Fatigue Life

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976
6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 1, January- April (2012), IAEME
288

INFINITE FATIGUE LIFE OF THREE LAYER SHRINK FITTED
COMPOUND CYLINDER UNDER FLUCTUATING INTERNAL
PRESSURE

Ayub A. Miraje
1*
and Dr. Sunil A. Patil
2

1
Asst. Professor, Dept. of Mech. Engg., MIT College of Engg, Pune, INDIA.
E-mail: aamiraje.mitcoe@gmail.com *Corresponding Author:
2
Prof. & Head, Dept. of Mech. Engg., Sinhgad Insti. Tech. Science,
Pune, INDIA.
E-mail: sunil_patil1963@yahoo.com

ABSTRACT

Reliability of materials of thick-walled cylinders is of critical importance to many
industries including power, nuclear, chemical, armament, and food processing industries.
Catastrophic failure of cylinders can put the human life at very high risk. Fatigue failure under
repeated or cyclic loading is a serious concern of engineering design. Under fatigue loading
the component may fail at a stress level that is far below its yield strength. If single cylinder is
used to store high pressure which is closer to the yield strength of the material, then thickness
will be very large. This paper introduces the methodology for minimization of volume of
shrink-fitted three layer compound cylinder to get infinite fatigue life in all cylinders. Stress
Life method based on S-N curves (StressCycle curves) is employed which deals with
relatively high numbers of cycles and therefore addresses High Cycle Fatigue (HCF), greater
than 10
6
cycles inclusive of infinite life. The analytical results using programming are
validated with FEM in ANSYS Workbench. Both the results agree with each other. Thus
methodology can be applied to multi-layer compound cylinders used in industrial
applications.
Keywords: multi-layer cylinders, hoop stress, residual stress, shrink fit, stress-life, infinite
fatigue life

INTERNATIONAL JOURNAL OF MECHANICAL
ENGINEERING AND TECHNOLOGY (IJMET)

ISSN 0976 6340 (Print)
ISSN 0976 6359 (Online)
Volume 3, Issue 1, January- April (2012), pp. 288-299
IAEME: www.iaeme.com/ijmet.html
Journal Impact Factor (2011): 1.2083 (Calculated by GISI)
www.jifactor.com

IJMET
I A E M E
289

1. INTRODUCTION
Majority of the mechanical failures are fatigue failures which are not expected.
Fatigue failures occur in every field of engineering including thermal, mechanical fatigue
failure in electrical circuit boards involving electrical engineers, bridges involving civil
engineers, automobiles involving mechanical engineers, farm tractors involving agricultural
engineers, aircraft involving aeronautical engineers, pressure vessels involving chemical
engineers, and nuclear piping involving nuclear engineers.
[Jahed et al., 2006] have used the actual material behavior to maximize the vessel life
through employment of shrink fit as well as autofrettage techniques simultaneously, according
to the extent and sequence that the optimum design would deem necessary. Several feasible
operational sequences have been investigated separately, yielding the most suitable scheme
after the optima of each has been determined accordingly. Design optimization was performed
for the thickness of each layer to lead to maximum vessel life expectancy under the
limitations imposed by total thickness and stress limits, as well as those of shrink fit and
autofrettage of each layer. [Patil, 2011] has investigated infinite life of two-layer compound
cylinder by using the optimization technique to determine the important design parameters
like interface diameter, outer diameter and diametric interference. He has found optimum
volume of compound cylinder to get infinite fatigue life (greater than 10
6
) for both cylinders.
Designer usually face the problem of determining maximum hoop stress or maximum
working stress to which shrunk-fit cylinder is subjected, the magnitude of shrinkage pressure
or any combination. The design of shrunk-fit cylinders is much simplified if each cylinder is
considered as a separate cylinder subjected simultaneously to the shrinkage pressure and the
working pressure. In this paper three cylinders are considered as shown in Figure 1. Cylinder
2 is shrink-fitted on cylinders 1 and cylinder 3 is shrink-fitted on cylinders 2.

a) Cylinder 1 b) Cylinder 2 c) Cylinder 3
Figure 1 Radial and hoop stress distribution in three separate cylinders

A multi-layered compound cylinder manufactured through a shrink fit process can
withstand higher pressure than a single cylinder having same dimensions. A compound
cylinder can increase residual stress and thereby enhance fatigue lifetime. The shrink fit
tolerance causes a compressive residual stress in the inner cylinder and a tensile residual
stress in the outer cylinder. The residual stress can be calculated by analytical method as well
as finite element method. This paper introduces the methodology to optimize volume of three-
layered compound cylinder to get infinite fatigue life.
290

2. LAMES THEORY APPLIED TO COMPUND CYLINDER
2.1. Shrink fit methodology
The inner radius of the outer cylinder may be made smaller than the outer radius of the
inner cylinder. The cylinders are assembled after the outer cylinder is heated and the inner
cylinder is cooled down.

a) Cylinders 1 and 2 b) Cylinders 2 and 3
Figure 2 Shrinkage allowance and contact pressures due to shrink fit
Considering three cylinders of same material, the method of solution for compound
cylinders is to break the problem down into four separate effects: i) shrinkage pressure
12 s
P
only on the cylinder 1 ii) shrinkage pressure
12 s
P and
23 s
P only on the cylinder 2 iii) shrinkage
pressure
23 s
P only on the cylinder 3 iv) internal pressure
i
P only on the complete cylinder.
2.2. Radial and hoop stresses in cylinder 1
If
i
P

= 0 i. e. no internal pressure, radial and hoop stresses due to shrinkage pressure
12 s
P only on cylinder 1 is given by using Lames equation.
2 2
2 1
12 2 2 2
2 1
1
r s
r r
P
r r r
| |
=
|
\

.. a)
2 2
2 1
12 2 2 2
2 1
1
s
r r
P
r r r
| |
= +
|
\
.. b) (1)
r
is maximum at outer radius
2
r of cylinder 1 . Using equation (1 a)

( )
2
12 max s r at r
P =

(2)

Using equation (1 b), hoop stress at inner radius
1
r and at outer radius
2
r ,
( )
1
2
12 2
max 2 2
2 1
2
s
at r r
P r
r r
=

=

.. a)
( )
2
2 2
2 1
12 2 2
2 1
s at r r
r r
P
r r
=
+
=

.. b) (3)
Using equations (2) & (3 a), radial displacement
1 r o
U at outer wall
2
r of cylinder 1 is
[ ] ( )
2 2 2 2
12 2 2 2 2 1 2 1
1 12 12 2 2 2 2
2 1 2 1
s
r o r s s
P r r r r r r r
U P P
E E E r r r r

| | | | + +
= = =
| |

\ \

(4)
Contact pressure
12 s
P is acting as internal pressure and contact pressure
23 s
P is acting as
external pressure on cylinder 2.
Radial stress in the cylinder 2 at inner radius

2
3
r is given by
( )
2
12 s r at r r
P
=
= .. a)
( )
3
23 s r at r r
P
=
= .. b) (5)
Hoop stress in the cylinder 2 at inner radius

2
3
r is given by
291

( )
2
2 2 2
12 3 2 23 3
max 2 2 2 2
3 2 3 2
( ) 2
s s
at r r
P r r P r
r r r r
=
+
=

a)
( )
3
2 2 2
12 2 23 3 2
2 2 2 2
3 2 3 2
2 ( ) ( )
s s
at r r
P r P r r
r r r r
=
+
=

b) (6)
Using equations (6 a) & (5 a), radial displacement
2 r i
U at inner wall
2
r of cylinder 2 is
[ ] ( )
2 2 2 2 2 2
12 3 2 23 3 3 2 23 3 2 2 2
2 12 12 2 2 2 2 2 2 2 2
3 2 3 2 3 2 3 2
( ) 2 2
s s s
r i r s s
P r r P r r r P r r r r
U P P
E E E r r r r r r r r

| | + +
= = = +
|

\

(7)
Using equations (4) & (7), total interference
12
at the contact between cylinder 1 and 2

2 2 2 2 2
12 2 3 2 23 2 3 2 1
12 2 1 2 2 2 2 2 2
3 2 2 1 3 2
2
s s
r i r o
P r r r P r r r r
U U
E E r r r r r r
| | | |
=
+ +
= +
| |

\ \
(8)
Using equations (9) & (11), radial displacement
2 r o
U at outer wall
3
r of cylinder 2 is
[ ] ( )
2 2 2 2 2 2
3 3 12 2 23 3 2 3 12 2 3 2
2 23 23 2 2 2 2 2 2 2 2
3 2 3 2 3 2 3 2
2 ( ) ( ) 2
s s s
r o r s s
r r P r P r r r P r r r
U P P
E E E r r r r r r r r

| | + +
= = =
|

\
(9)
Contact pressure
23 s
P is acting as internal pressure on cylinder 3 and external pressure
o
P

is zero. Radial stress in the cylinder 3 at inner radius
3
r is given by
( )
3
23

s r at r r
P
=
= (10)
Hoop stress in the cylinder 3 at inner radius
3
4
r is given by

3
2 2
23 4 3
( ) 2 2
4 3
( )
s
max atr r
P r r
r r
=
+
=
.. a)
4
2
23 3
( ) 2 2
4 3
2
s
atr r
P r
r r
=
=
.. b)

(11)
Using equations (10) & (11 a), radial displacement
3 r i
U at inner wall of cylinder 3 is
[ ] ( )
2 2 2 2
3 3 23 4 3 23 3 4 3
3 23 2 2 2 2
4 3 4 3
( ) ( )
( )
s s
r i r s
r r P r r P r r r
U P
E E E r r r r

+ +
= = = +

(12)
Using equations (12) & (9), total interference
23
at the contact between cylinder 2 & 3

2 2 2 2 2
23 3 4 3 3 2 12 3 2
3 2 2 2 2 2 2 2
4 3 3 2 3 2
2
s s
r i r o
P r r r r r P r r
U U
E E r r r r r r
23
| | | | + +
= = +
| |

\ \
(13)
Hoop stress in three-layer cylinder due to internal pressure
i
P

only at any radius r is

2 2
1 4
2 2 2
4 1
1
i
Pr r
r r r

= +

(14)
2.5. Principal of Superposition for three-layer compound cylinder
After finding hoop stresses at all the radii, the principle of superposition is applied, i.e.
the various stresses are then combined algebraically to produce the resultant hoop stresses in
the compound cylinder subjected to both shrinkage pressures,
12 s
P and
23 s
P

and internal
pressure
i
P .
292

a) Hoop stress due to
i
P b) Hoop stress due to
12 s
P &
23 s
P (c) Resultant hoop stress
Figure 3: Superposition of hoop stress due to
i
P & hoop stresses due to
12 s
P &
23 s
P

Using equations (14) & (3 a), maximum hoop stress at the inner surfaces of cylinder 1 (
1
r ) is
2 2 2
4 1 2
1max 12 2 2 2 2
4 1 2 1
2
i s
r r r
P P
r r r r
+
=

(15)
2
r ) is
2 2 2 2 2 2
1 12 3 2 23 3 4 2
2max 2 2 2 2 2
2 4 1 3 2
( ) 2
i s s
Pr P r r P r r r
r r r r r
+ +
= +

(16)
3
r ) is
2 2 2 2 2
1 4 3 4 3
3max 23 2 2 2 2 2
3 4 1 4 3
i
s
Pr r r r r
P
r r r r r
+ +
= +

(17)
3. OPTIMUM DESIGN METHODOLOGY FOR INFINITE FATIGUE LIFE
3.1. Analytical Method for Fatigue Life of cylinder 1, 2 and 3
Let the ratios
2 2
1
1 1
r d
C
r d
= = ,
3 3
2
2 2
r d
C
r d
= = ,
4
3
3 3
4
r d
C
r d
= = (18)
where
1 2 3 4
, , , d d d d are diameters corresponding to radii
1 2 3 4
, , , r r r r .
Using
1 2
, C C and
3
C , equations (15), (16) and (17) can be rearranged as follows,
2 2 2 2
1 2 3 1
1max 12 2 2 2 2
1 2 3 1
1
2
1 1
i s
C C C
C
C
P P
C C C
+
=

(19)
2 2 2 2
2 3 2 2
2max 12 23 2 2 2 2 2
2 3 2 2 1
1 1
2
1 1 1
i s s
C C C C
P P P
C C C C C
+ +
= +

(20)
2 2
3 3
3max 23 2 2 2 2
2 1 3 3
1 1
1 1
i s
C C
P P
C C C C
+ +
= +

(21)
Minimum hoop stresses in the cylinders 1, 2, 3 without internal pressure
i
P at inner radius
1 2 3
, , r r r respectively is given by
2
1
1min 12 2
1
2
1
s
C
P
C

,
2 2
2 2
2min 12 23 2 2
2 2
1
2
1 1
s s
C C
P P
C C
+
=

,

2
3
3min 23 2
3
1
1
s
C
P
C
+
=

(22)
Putting the values of
1 2
, C C and
3
C , the equations (8) and (13) can be written as
293

2 2 2
2 2 1 2 2
12 12 23 2 2 2
2 1 2
1 1 2
1 1 1
s s
r C C r C
P P
E E C C C
| | | | | | + +
= + +
| | |

\ \ \
(23)
2 2
3 3 3 2
23 12 23 2 2 2
2 3 2
2 1 1 1
1 1 1
s s
r r C C
P P
E E C C C
| | | | + +
+ +
| |

\ \
= (24)
Let
2 2
2 2 1
1 2 2
2 1
1 1
1 1
r C C
K
E C C
| | | | + +
= +
| |

\ \
,
2
2 2
2 2
2
2
1
r C
K
E C
| |
=
|
\
,
3
3 2
2
2 1
1
r
E C
K
| |
|
\
= ,
2 2
3 3 2
4 2 2
3 2
1 1
1 1
r C C
K
E C C
| | + +
+
|

\
=
Hence equations (23) and (24) becomes
12 12 1 23 2 s s
K P P K + = (25)

23 12 3 23 4 s s
P K P K + = (26)
Solving equations (25) and (26) for
12 s
P and
23 s
P

we can get
12 12 4 23 5 2
( ) /
s
K P K K = (27)
23 12 3 5 23 1
( ) /
s
P K K K = (28)
where
5 4 3 2 1
K K K K K =
Material for all the three cylinders is considered as linear isotropic (AISI 1020 Steel)
with properties i)
y

(Yield strength = 250 MPa ) ii)
u
(Ultimate strength = 460 MPa )
iii)
e

( Endurance strength =125 MPa ) iv) (Poissons ratio = 0.3 ) v) E = 210000 MPa.
Three layer compound cylinders are analyzed for high cycle fatigue load using stress
life method of computing life in number of cycles. Cylinders are applied with fluctuating
internal pressure varying from 0 to 250 MPa.

Mean Stress Corrections for Stress Life

For Stress Life, if experimental data at different mean stresses exist, mean stress can
be accounted for directly through interpolation between material curves. If experimental data
is not available, several empirical options may be chosen including Gerber, Goodman and
Soderberg theories which use static material properties (yield stress, tensile strength) along
with S-N data to account for any mean stress. In this study, a Goodman criterion is used for
mean stress correction theory.

Three cylinders are subjected to mean stress and alternating stress. Maximum hoop
stress is major stress which is responsible for failure. Maximum principal stresses in all the
cylinders (here it is maximum hoop stress) should not exceed the yield strength of the material
to avoid the failure of the compound cylinder.

Mean stress, Alternating stress and Equivalent Alternating stress and Fatigue Life in
three cylinders is calculated using following equations.

294

Cylinder 1 Cylinder 2 Cylinder 3
1max 1min
1m
2
ean

+ | |
=
|
\

2max 2min
2 m
2
ean

+ | |
=
|
\

3max 3min
3m
2
ean

+ | |
=
|
\

1max 1min
1
2
v

| |
=
|
\

2max 2min
2
2
v

| |
=
|
\

3max 3min
3
2
v

| |
=
|
\

( )
1
1
1m
1 /
v
eqv
ean u

| |
=
|
|
\

( )
2
2
2m
1 /
v
eqv
ean u

| |
=
|
|
\

( )
3
3
3m
1 /
v
eqv
ean u

| |
=
|
|
\

( )
( ) ( ) ( )
1
3 log 0.87 log
3
l
1
og 0.87 log
10
u
eqv
u e

| | | | | | | |
| | | |
\ \ | \
|
|
|
\
=

( )
( ) ( ) ( )
2
3 log 0.87 log
3
l
2
og 0.87 log
10
u
eqv
u e

| | | | | | | |
| | | |
\ \ | \
|
|
|
\
=

( )
( ) ( ) ( )
3
3 log 0.87 log
3
l
3
og 0.87 log
10
u
eqv
u e

| | | | | | | |
| | | |
\ \ | \
|
|
|
\
=

3.2. Steps in Optimum Design
Optimum volume (length is assumed as unity) for infinite fatigue life can be calculated
using following steps. For the given volume of fluid to be stored, the internal diameter of
cylinder 1 is known.
1. Assume internal diameter of cylinder 1 (
1
d ) say 100 mm.
2. Select the ratios
2 2
1
1 1
r d
C
r d
= = ,
3 3
2
2 2
r d
C
r d
= = ,
4
3
3 3
4
r d
C
r d
= = and
12
,
23

3. For the given internal pressure
i
P , one can find contact (shrinkage) pressures
12 s
P and
23 s
P in terms of ratios
1 2
, C C
,
3
C and interferences
12

,
23

using equations

(27) and (28).
4. Find the volume of the compound cylinder using
2 2
4 1
.( ) / 4 Fx d d =
5. Minimize the volume subjected to the constraints,
i)
1max y
<=

ii)
2 max y
<= iii)
3max y
<= iv)
12
0 > v)
23
0 >

vi)

6
1
10 >=
vii)
6
2
10 >= viii)

6
3
10 >=
6. Optimized parameters
1 2 3
, , C C C and
12 23
, are used for the design.
Various values of
1 2
, C C
,
3
C
,
12

and
23
are used and using iterative numerical method
(with the help of computer programming), contact (shrinkage) pressures
12 s
P and
23 s
P for given
internal pressure
i
P are calculated. Volume is minimized subjected to the above said
constraints where one can get infinite fatigue life of all three cylinders (
1 2 3
, , ) which is
greater than 10
6
cycles. Optimized parameters are shown in Table 1.

Table 1 Results of Computer Programming

INFINITE FATIGUE LIFE OF 3-LAYER COMPOUNDCYLINDERS
OPTIMIZED PARAMETERS ARE AS FOLLOWS
1
C =1.700
2
C = 1.200
3
C = 1.600
12
= 0.070(mm)
23
= 0.080(mm)
1
d = 100.00 mm
2
d = 170.00 mm
3
d = 204.00 mm
4
d = 326.40 mm
Minimum Volume corresponding to optimized parameter = 75818.342 mm
3

1max
= 51.946 MPa
2max

= 126.154 MPa
3max

= 248.476 MPa
1min
= -249.847 MPa
2min
= 4.791 MPa
3min
= 156.284 Mpa
295

Fatigue Life of Cylinder 1
1
= 1039659.075 Cycles
2
= 29328512.149 Cycles
3
= 11946167.600 Cycles
Contact Pressure between cylinder 1 & 2
12 s
P = 81.697 Mpa
Contact Pressure between cylinder 2 & 3
23 s
P = 68.484 Mpa

4. VALIDATION OF RESULTS BY FINITE ELEMENT APPROACH

By taking the parameterized values of
1 2 3
, , C C C from Table 1 and taking internal
diameter of cylinder 1 as 100 mm remaining diameters are calculated which are listed in
Table 2. Using the values of
12 23
, shrink fit is applied between cylinders 1 & 2 and between
cylinders 2 & 3 respectively in ANSYS Workbench. Contact between cylinders 1 & 2 as well
as between cylinders 2 & 3 is applied using contact tool in ANSYS Workbench. The values of
12 23
, are radius based. These values are doubled to take diametric effect in the Finite Element
Model as shown below.

Table 2: Data for modeling in ANSYS to validate analytical results

1
C
2
C
3
C
1
d

2
d

2i
d

3
d

3i
d

4
d

12

23

1.7 1.2 1.6 100.00 170.00 169.86 204.00 203.84 326.40 0.07 0.08

where
1
d ,
2
d inner and outer diameters of cylinder 1.
2i
d
,

3
d inner and outer diameter of cylinder 2 respectively for shrink fit.
3i
d
,

4
d inner and outer diameter of cylinder 3 respectively for shrink fit.
4.1. Contact Tool in ANSYS Workbench
Using contact tool in ANSYS Workbench, rough contact between cylinders 1 and 2
and between cylinders 2 and 3 is made as shown in the Figures 4 and 5.

Figure 4 Contact between cylinder 1 & 2 Figure 5. Contact between cylinder 2 & 3

296

4.2. Fatigue Tool in ANSYS Workbench
Loading ratio is calculated on each cylinder by considering maximum and or
minimum hoop stress with and without internal pressure. Fatigue load is applied on each
cylinder using calculated loading ratios as shown in the Figure 6.

Loading Ratio = 0.275 Loading Ratio = 0.209 Loading Ratio = 0.629
Figure 6 Fatigue load on cylinder 1, 2 and 3 resp.

5. RESULTS AND CONCLUSION

Figure 7 Maximum Hoop Stresses in cylinder 1, 2 and 3 resp. with internal pressure
i
P

10
6
number of cycles 10
6
number of cycles 10
6
number of cycles
Figure 8 Fatigue Life in number of cycles for cylinder 1, 2 and 3 resp.

297

Figure 9 Fatigue sensitivity of cylinder 1, 2 and 3 resp.
Analytical results and FEM (ANSYS) results are summarized in Table 3.

Table 3: Comparison of Analytical and ANSYS results

Parameters

1max

2max

3max

1

2

3

12 s
P
23 s
P
Analytical 51.946 126.154 248.476 1039659 29328512 11946167 81.697 68.484
ANSYS 65.560 136.620 249.250 10
6
10
6
10
6
83.000 68.840

From the table 3, it is observed that there is very small difference in analytical and
ANSYS Software results. This difference is due to numerical techniques of Finite Element
Method in ANSYS. FEM gave virtually similar results as the analytical results. Fatigue life
for optimally designed three layer compound cylinder is more than 10
6
cycles giving infinite
life under fluctuating internal pressure. Thus this methodology can be applied for multi-layer
compound cylinders used in mechanical applications.

NOMENCLATURE

i
P Internal pressure acting on the cylinder 1
o
P External pressure on the cylinder 3
Hoop stress in the cylinder

r
Radial stress in the cylinder
1
r Inner radius of cylinder 1
2
r Outer radius of cylinder 1 and Inner radius of cylinder 2
3
r Outer radius of cylinder 2 and Inner radius of cylinder 3
4
r Outer radius of cylinder 3
12 s
P Contact pressure between cylinder 1 and 2
23 s
P Contact pressure between cylinder 2 and 3
1 r o
U Radial displacement at outer wall of cylinder 1
2 r i
U Radial displacement at inner wall of cylinder 2
12

Total interference at the contact between cylinder 1 and 2
2 r o
U Radial displacement at outer wall of cylinder 2
3 r i
U Radial displacement at inner wall of cylinder 3
23

Total interference at the contact between cylinder 2 and 3
298

Poissons ratio
E Modulus of Elasticity
1max
Maximum Principal (Hoop) stress in cylinder 1
1min
Minimum Principal (Hoop) stress in cylinder 1
2max
2min
3max
3min
1mean
Mean stress in cylinder 1
2mean
3mean
1v
Alternating stress in cylinder 1
2v
3v
1eqv
Equivalent alternating stress in cylinder 1
2eqv
3eqv
1
Fatigue life of cylinder 1 in Number of cycles
2
3
y

Yield strength
u
Ultimate strength
e

Endurance strength
ACKNOWLEDGEMENT
The author is grateful to the Management, Executive Director, Principal, Head-
Department of Mechanical Engineering of MIT College of Engineering, Pune, India for time
to time encouragement and support in carrying out this research work.
REFERENCES
[1] Browell R. and Hancq A.(2006), Calculating and Displaying Fatigue Results, Ansys
Inc.
[2] Gibson M. C. (2008), Determination of Residual Stress Distributions in Autofrettaged
Thick-Walled Cylinders, Ph. D. Thesis , Cranfield University, Defense College of
Management and Technology, United Kingdom.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976

Hoop stress in the cylinder

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