Proceedings of PVP2007

2007 ASME Pressure Vessels and Piping Division Conference

PVP 2087
July 22-26, 2007, San Antonio,
Texas
2007 ASME Pressure Vessels and Piping Division Conference
July 22-26, 2007, San Antonio, Texas

PVP2007-26010

THE DESIGN OF RECTANGULAR METAL BELLOWS

Rsbe~
K,Broyles
Senior Flexonics Pathway Inc,
2400 Longhorn Induskial Drive
New Braunfels, Texas 78130
Telephone: (830)629-8086
Ernail: broy%esb@pathwayb.com

L Length o f bellows rail or beam (in)

L, Mean length of bellows short "&side$in)

ABSTMCT
Rectangular metal expansion joints are
only used in
flue gas dexcwork, t u b h e exhaust systems,
at exchanger
applications. The Standards of" the Expansion Joint
Manufacmers Assoeiatlsn (EJh4A) are widely referenced f i r
the design of rectangular metal expansion joints. The $3'
edition, 200.5addenda, contains equations for rectangular metal
bellows pressure stresses, movement stresses, heam lateral
and spring rate, This paper evaluates the
deflection, fatigue $
accuracy of the E$
equations based on failwe reports and
FEA studies, Both linear eelastie and noa-1hear limit analyses
are used for the evaiuations, Improved methods are proposed
for the detemination o f pressure capacity, beam deflection,
moment o f inertia, and comer rigidity, New lateral deflection
limits and acceptance criteria are provided herein* This paper
also includes design considerations fbr the pressure stops used
to support bellows rails,

Li

Mean length o f bellows long side (h)

L, Bellows tangent length.

i$f, Piastic momerat (in-ibs)
M,,, Plastic moment though the weid (iwlbs)
My Yield moment (in-lbs)
N Kumker o f convolutions
N, Number of equally spaced pressure stops

Pressure (psig)
Convolution pitch (in)
,Mean radius o f ~onv01utiollt(in)
Bellows material aPlowabBe stress (psi)
Max, bending stress (psi)
Sbc Max, bending stress for co$%apse
load (psi)
Sbl Max, bending stress for long rail (psi)
Sbs ~Vax,bendigbg stress for short rail (psi)
S, Design stress htensiw (psi)
Sy Yield s&engtkl (psi)
t
Nominal material thickness (in')
h,
Equivalent material thickness (,in)
w Cornvol~~xicors
height (in) or unit Isad (Ibs/h)
wC Unit callapse load (lbsiin)
yi Max, deflection for Long rail (in)
ys Max. deflection for short rail (kg
Z Section modulus (in')
Z, Piastic modulus (in3)
a Angle ofthin sloped rectangle (deg)
q
r,
Sab
Sb

NOMENCLATURE
Cross sectional area o f one convolution (in2)
b
I,en@h o f thin doped rectangle (in)
C, Bellows a a a c h e n t factor
e
Total equivalent axial mvmt per convolution (in)
Eb BeZFows modulus of elasticity at design temp (psi)
I Moment of inertia of bellows cross section (in')
1,
Moment of inertia of 90 drg arc (ind)
I, Moment of inertia o f thin sloped rectangle (in4)
K, Shape Factor
A,

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INTRODUCTION
This study began when a rectangular metal bellows failed
catastrophically at a presslare wedl beiow that predicted $4 the
equations contained in the EJLW Standards, gLhedition, 2005
addenda [I], The compmy that rnmufacl;k~r.l-ed
the bellows is an
EJMA member with over 40 years of experience The be~lsws
was located in the exhaust duet between a large steam turbine
and its condenser, Prior to reaching the operating condition of
full vacuum, the convolutions suddenly collapsed inward, The
for an
equations given in the EJMA Standards rated the $C~%$DWS
external design pressure of 30 p i g , which i s %ice ahe operating
pressure of"the system, As1 investigation into this disparity
lrightighted the followhg deficiencies in the EJbIA equations:
a) The equations for Xcangimdinal bending stress and
deflection give values that do not match F'EA results.
b) The equations do not consider that diEesent ar~alysis
methods me required for bellows with high E/T and o w Lil
ratios,
c) The equations do not consider the detrimental impact of
unsuppofied bellows tangents,
d) The moment o f inertia equation i s not accurate for **%i""
shaped esnvolk8";ions,
e) The relative rigid13 o f diEerent comer types i s not
addressed by the equdtisns,
No equations are provided for finding the load on pressure
stops added to support the bellows between the comers,
g) The kellows shape factor i s not considered in the bending
stress acceptmce criteria,
h) There i s no acceptance criterion for laterat deflection,

support all of the load, To address these two possiksiliaies, a two

step analysis rnetl~asdi s used,
The analysis method begins bj asseming a bellows design
and then treating it as a short rail, If %hatapproach failis to meet
the acceptance criteria, the design is treated as a long rail, If
both approaches fail, the bellows design i s changed and the
steps are repeated until a succes~ful design emerges, For
tangents that are fully supported against the pressure, the
assumed tangem length will be zero, For a one-convolution
bellows, the assumed lateral deflectiorr and bending stress will
be zero,
For this paper, movennent perpendicular to the axis o f the
bellows rail i s defined as lateral deflection,

BELLOWS MOMENT OF INERTIA

The cross scction shorn in Figure 1 represents one half o f a
rectangular beflows C O ~ ~ O ~ U I$n~EJhL4,
O ~ , the same naomentoof
inertia equation is given for boll "Uq9and *'VV"'shape profiles,
Comparative calculations show that the equation i s fairly
accurate for '"U" profiles btb erroneous for L'V'9profiles, For
example, consider a "'V" profile bel4ows with w = 55,
q --- 2-5, t =
-062,
rnl= 0-25,
and K = I, The EJMA equatiori gives 1 =- 1-80
in! The actual rnomenr of inertia i s 1.53 in" representing an
18% emor,

The intent o f this paper is to veri@ the accuracy of existing

equations and propose improved equations based on linear
elastic FEA, non-linear FEA, and failure reports, FEA i s
performed using a co ercially available program [2].

ANALYZING A BELLOWS FOR LONGITUDINAL"

BENDING STRESS DUE TO PRESSURE
The side of a rectangular bellows (isem,rail') can be treated
as a beam, As shorn later9the ends of the beam (i,e,, comers)
provide a hi& degree sf rigidity. T h e beam has a miformhy
distributed load due to pressure along i t s length. The stress
generated by tdae uniform load i s defined in EJMA as the
Iongimdinal bending stress, To calculate %ongi$a;idinal
bending
stress and lateral deflection: the bellows rail i s treated as a beam
with a mifoxmly distributed load along its length. The bel'ows
rail is also supported along its length wl~erei s a&aches to the
ducting, Some o f the load on the bellows is resisted by the
attachments, For shon rails with low LJI ratio, the hngact i s
negligible, Tor long rails with high ]%/I rdpiio)the akB:achents

Figure 1 - Convolution Detail

Io simpli@ the calculation and produce a more accurate
approximation for the rnonnent o f inertia, the convolr~tion i s
treated as a thin sloped rectarlgir with a 90-degree arc at each
end The moment o f inertia of a thin sloped rectangle about the
convolution neutral axis i s given by

Longitudinal refers to stress in a direction along the length of

the rail and i s used fo"9sroalsistency with the EJIMA Standards.
H~~~~~~~
shows a
beliows design
be limited by bending
in the direction perpendicular to
the length of the rail ("a.e,:rneridlonal direction),
I

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BELLOWS SHAPE FACTOR

To fmd the acceptance criteria for rzclarggular bbel%o.rihbs
bending stress, the shape factor o f the cross section must be
determined, The shape factor i s the ratio o f the plastic rnomenr
to the yield moment $31 or

'The plastic moduibps (Zp)

i s the first moment of the cross
sectional area with respect to the neutral axis 83j or

Using the parallei axis theorem, the moment of media o f a thin

90-degree arc about the convoXution neutral axis i s given by

Ireating the convoiiution as a thin sloped rectangle witla a 90'

arc at each end, the plastic modulus i s given by

The moment for inertia for S convo%utionsBS

Using these equations, the shape Pictor for a '"V==

shape profile
where r,, = O is 1,s and the minimum shape factor for 2114
bellows profile i s 2 -31.
CORNER RlGiDiTY
Rectangular naletal bellows have different types of comers as
shown on Figure 2,

The equation can be simplified by roundkg off the constants

and eliminating the second term, which i s always negligible
relative to the total value,
The simplified moment o f inertia equation far N convo3u~ionsis

1 or a ""U9shape profile where ,r

to the EJMA equation or

q/4, the equation reduces

It shorldld he noted that these equations do not ksclude the

moment sf inertia o f the tangents or the eRect o f bellows
movements.

Figure 2 - Corner Types

EJiMX does not address the relative rigiditj o f the corners,
Relative comer rigidity can be determined by comparing the

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center fateapal deflection sf a single convolution rail having

diRerer~tcomers with the same rail having fixed and simply
suppo~edends, Linear eelastic FEA was used with models
having 4 node thin shell elements with 6 DOF per node, Except
for the type of comer or ends, the models all have identical
dimensions, boundary conditions, and loading, Figure 3 shows
the model for a single miter comec The rail ends habe
etrical boundary conditions and the edges along the length
are fixed in fhe X direction, Uniform pressure i s applied. on a11
of the inside surhces.

to the center. One end o f the model i s fixed while the moving
end has syrmctricai bswdav conditions, The edges along the
length are fixed in the X direction, Uniform pressure is applied
on all o f the inside surfaces, The profile is also typical for a
standard fixed ecd beam with a uifom load.

Figure 4 - Shod Rail lateral Deflection Profile

Based on standiard beam eequatioras for a beam with fixed
ends [4j,the maximum bending stress at the ends i s

Figure 3 --- Corner Model

The maximum lateral deflection at the center i s

'E'he results of the study are shown in Table I. At the center sf

the rail, the lateral deflecticrs $br the specified comer divided by
the lateral deflection wit11 rigid ends i s defined as the deflection
rxio The ratio for the 12" mund comer is less than one
because the rail length i s eEeetively reduced by the radius,

SbgBe Miter Garner

1 Double Miter Comer

0,893

/0.918

LONG MiLS
Long bellows have high L/I ratios, Although fixed at the
comers, the tangents along fhe length actually support the rail,
Figure 5 sl~or,vsthe exaggerated deflection profile of a long rail
from the fixed end to the center, One end and the edges sf the
anode1 are completely fixed while the moving end has
etrical bornday conditions, Uniform pressure i s applied
on ail s f ~ h inside
e
s~nfaces,

122

11-26 1

--

Round Coaner ( 12" inside

Table 1 - Rail Lateral Deflection Ratios

As expected, the deflection ratio for simply supported ends
i s exactly "; Since the deflect"8on ratios for the various comer

types are very close to 1, the comers can be considered

essentially rigid for the analysis o f bellows longitudinal bending
stress,

Figure 5 --- Long Raii Deflection Profile

The profile shows that the deflection increases and then
becomes constant, The length with constant deflection indicates
that only the tangents are supporting the rail, Therefore, the
maximum deflection can be found by considerhg a unit wide
strip o f beZIaws that is fixed at the ends and bas a uniformly
distributed load, KTe will First assume that the bellows has a
tangent length sf zero, Since the bellows i s convoluted, the
maximum deflection o f the bellows strip does not confom~to

SHORT MILS
Short rails have %ow Lil ratios and receive negligible
support from the tangents along the length o f the rail,
Therefore, they can be treated as a fixed end beam with a
amifomly distributed ksad along i t s length, Figure 4 shows the
exaggerated deflection profile of a short rail from the fixed end

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s~andasd beam fc~nnkaiae,

approximate the maximum
deflection, lin~~ezr
elastic FEA was used, A series of wit width
parametric models were created for both "IJ"and -*.$p'" shaped
convoi%s$ionsusing 8 node isoparamekic shell ekements with 6
DO%"per node, The results were tabulated and correlated to
develop the focsllouing equation for maximum lateral deflection

Rectangular metal bellows nomallj have tangents, The

assumption o f zero tangent length means that the tangents are
fully s u p p o ~ s dagainst the pressure, If the tangents are
k114
supported against the pressure, the tangent length must be
considered, Tangents no"eu1Bq suppsned against the pressure
eEectivelj increase the length of the bellows across the
convolutions, The tangents deflect under pressure, increasing
the total deflection and bending stress in the bellows, This case
earn be treated as a beam with unit width, fixed ends, uniformly
distributed load, and length ofNq 2L,,
+

By subs.aitu~iono f mq

7 2Ldt)i'Fai for q i
n equation 14, tkae
eEective doichess equation becomes

Table 2 compares the results of FEA and equation 11 for

several randomly selected bellows profiles where Eb =
29,00a3,000psi and P == 1,0p i g ,

By substitu%ia>n
of Nq 4-2L,for Kq in equation 13,the equat~on
for m a x i m u lateral deflection becomes

By substitution o f Nq + 2L,for 1, in equation 9,the maximum

bending stress at the ends becomes
Table 2

.--

FEA vs, Equation Resulb

The maximum error o f the equation values with respect to the

FEA values is only 8,594over a wide range of bellows profiles,

When the tangents are fully supported against the pressure,

We can find the equivalent thickness for a uniform

L,should be set to zero in the above equations,

rectangular beam wifh the same maxhum lateral deflection as

the convoluted section of the beBlows, For a beam o f lanit width
with f~xedends, a ~mifomlydistributed load, and length Nq, the
standard eqwation for max deflection [ih] i s

'

ACCEPTANCE CR%TERIA
As s h o w by Salmon and $ohson 151: the collapse
condition for a fixed end beam with a, uniformly distributed. load
occurs when plastic hinges form simultaneously at the ends and
the center of the beam, Using a free body diagram, the
equilibrium equation i s

"

12w(xq)
P(N~)
h"%axim~m
Deflection = - - - - = - 384IZ,te3 32Ebt,3
Senkg equation i 2 eqa1a.l to equation I I gives

The plastic moment i s

Solving for the equivalent thickness gives

Therefore, by substitution the collapse load i s

(14)

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'She equation for mfiaximmr bending stress at the ends o f the

beam is

'rhe collapse load i s

'Therefore, the ealcuXated rnaxhbikm bending sfress for the

collapse load is

The caicufated max, bending stress for the coB1apse load i s

This result was eonfinned by FE lirn18 analysis.

ASIME Section VIll, Div, 2, Par*4 - 136-3161 requires that
the design load not exceed 213 of the "awes bound collapse
load, It also requires that the yield strength used in collapse Isad
ea~eulationsbe H Xirn,Since the ealcullated maximum bending
stress in uniaxial, i.l;i s also the stress intensity, Therefore, the
c%esi.jpbending stress limit is

Ti~erefore,the design bending stress li1ni2 is

Tor a rectangular shape beam attached at the elads bj fillet

welds, K,= 1.5and the bending stress limit becomes
Since the tabulated balue of Sabis less than or equal to the value
o f S,, Sabmay be used in place o f S,, for convenience

This result was csnfimed by FE limit analysis.

For a rectangular shape beam aaached at the ends, K,

and the bending stress limit becomes

The aforementioned bending stress limits for beams can be

applied to rectangular bellows, For short rails, the bending
stress limit is

1-5

For long rails, the bending stress limit as

There is a special case when fillet welds attach the ends of
the beam and the weld thoat thickness i s 0,"?07t, Using a free
body diagram and the eqaliiibrium method, the equi%i"ssrium
equation is

where
C,= 2 when the tangents are supported so bending at the ends
occurs through the LIB1 thickness of the material

nrsa: supported so bending at the

C,== % -5when the tangents are

ends occurs through fillet welds,

ANALYSIS STEPS
The steps for fmding the beflows XsngitudinaB bending stress
and lateral deflection are as bllows:

The plastic moment though the ~ e l throat

d
is

la,

Select a bellows design.

Therefore, by substikution the equilibrium equation i s

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Table 3 compares FEA results with the nevv equalions in this

paper. The FEA max, deflection i s based on tinear eelastic
analqsis, The FEA max, design pressure is based on non-linear
limit arsalysis using a Tresca elastic-perfectly piastic material
model, the New-ton-Raphson iterative method, and ehe yield
strength set at SabaFor these cases Sab= 28000 psi and Eb -29,000,000psi.

3, If Sbsct 1.33KsS,,, the design i s acceptable, Ihe maximum

bending sbess is S,, arid the maxianurn lateral deflection if
y,, IfSb,> 1-33K,Saa, goto step4.

5, If SD1 5 C, Sab, the design

i s acceptable, The maximum

bending stress is Sbiarid the rnax~anaumdeflection i s yl, If Sbi
> C,Sab.go to step 6,

4,

Redesign the bellows and go back to step 2 ,

Note - For tangents that are fully supponed against the pressure,
set L,= 0 in the calcuiations, For N =I, the maximum bending
stress and maximum Iateraf deflection are assumed to be zero.

METHOD VERIFBCATiON
To confirm the accuracy o f this method, several verification
cases &erg: developed to compare FEA and equation results,
Cases I and 2 are examples of long rails, The FEA model
show3 kri Figure 6 uses 8 node plane 2 0 elements with 2 DOE
per node, The attachment ends o f the model are fixed and
uniform pressure is a ~ d i e don the inside,

Table 3 --- Verification Case Results

'The coqarison shows that the equations are very accurate
with respect to the FEA results,

Figure 6 FEA Model for Cases 1 & 2

---.

Case 3 is an. example of a short raid and i t s FEA model uses 8

node isopar-amekic shell elements wish 6 D8F per node, The
model is shown in Figure 7,One enld of the model i s fixed and
the moving end has s
et~ica8boundav conditions, The
edges along the length are fixed in the X direction, 1Jnifom
pressure i s applied on all o f the inside surfaces,

In addition to FEA, a failure report was used to check the

equation accuracy, The T304 stainless steel beellows had w = 2
ha,
q ==2in,, t = 41-05in., W = 2,L,= I, L = 170 ins,and S,, =269000 psi, The bellows suddenly eoliapsed inward in a system
that a;>peratesat full vacuum, Since full vacuum i s an absolute
pressure limit, we b o w miith certainty that the beilows failed at
or below 14,7psig, The equations would be in emor if they
predicted a coldapse presswe above 14-7psig, The equations
give a max, design pressure of 4.17psig for this beliows, The
mil%certification for the belBows material gives the actual yield
s%sen@has 43,000psi, Therefore, the collapse pressure based
on the equations i s 4,1~43000/286>QPO)
= 897 psig which is less
than 34-9 psig, The new method predicts failure o f the bellows
before ereaching the operating condition,
LONGlTUDlNAL MEMB, STRESS FROM PRESSURE
The E J M Standards give equations for finding the
Iongihdinal membrane stress h the bellows due to pressure.

Figure 7 --- FEA Model for Case 3

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C~onsiderhgths bellows as a fww-sided kame, the membrane

stress results fiom the Irangihdinal tension or compression load
applied on each 1x81by the two opposing rails, The EJMA
equations are as folLows:

Hf S8,,<: 1.33 K,Sab, then ysmi = y b r ~ a

If Ssx, " 1.33 K,Sab, then yhmi = yhmlb

If the tangent is fully supported agahssst the pressure, set L,---. 0,
I f N = 1 , set ybmi = 0, The equations for ybmsare found in the
same mamer,
IfN

=;

MERIDIBNAL BENDlNG STRESS FROM PRESSURE

The EJbM Standmds give
equation for fmding the
rneridional bending stress in the bellows due to pressure, The
direction of rneridiona! stress is across the convolutions from
tangent to tangent, Excessike meridional bending stress can
result in gross plastic defamation in tthc root, crest, and
sidewall, The EJNIA equation i s

I, set S7iand S7s= 0.

LONGIWDINAL BENDlNG STRESS FROM PRESSURE

The EJMA Standards give equations for fmdhasg the
lo~~gihdirmal
bending stress in the bel!ows due to pressure, This
bending stress results from the inward or oubvard deflection of
the beilsws rails dale to pressure. As indicated, the existing
equations are mot acclaate, Based on the new methodology
described above, the EJMA equations may be revised to the
fol1owing:

To verify the accuracy o f this equatiorz, a paranaenie FEA

study was perfomed with thxee diEerenk cases, The models use
8 node plane 2D elements (2 DOF pel- node) with 8 elements
across the thickness,For the cases, P =: 15 p i g . The FEA model
for case 5 i s s % ~ oin
w Figure 8,Orre end o f the model is fixed
and the other end has symmetrical bounday conditions.
Uniform pressure i s applied on the inside,

If Ssi, 2 1 3 3 KsSjib.,
then Sial Ssa,
=I

If the tangent i s fully supported against the pressure, set L,, --- 0
in the calculations, If N = 8, set SB1= 0.
The equations for S8,are found in the same manner

BELLOWS DEFLECTION FROM PRESSURE

The E J M Standards give equations for finding the inward
or ourward lateral deflection sf the bellows rails due to
pressure, As indicated, the existing equations are not accurate,
Based on the new methodoliogy described above, the EJMA
equations may be revised to the fol!o.avir%g:

Figure 8 - FEA Model for Case 5

The comparison between FEA results and the equation is
arized in Table 4, It i s apparent that the equation for
meridional bending stress due to pressure is reasonably accurate
with respect to FEA results, The max, emor for the cases
examined i s less than 1996,

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MERIDIONAL BENDING S"%"RESSFROM MOVEMENT

The EJiMA Standards ghe an equation for finding the
n~esidionai bending stress in the bellows due to beliaws
movements, The rneridrsnal hending stress i s used to determine
the faxigare life o f the bellows, The EJMA equation is

S,,

S8,.<c 1,33K,S,,, when Sha 5 1.:%34Sai:

S,,SC, S,, wheaS,,,;

To verifj the: accuracy of this equation, a parametric FEA

study was performed using thee different cases, For the cases,
e = 0-5in,and Eb = 29,000,000psi, The model for caw 5 i s
shswa in rigre 8,The comparison between FEA results and
the equation is su~rimarized in Table 4, The equation for
rneridional bending stress from beellows movement 4s very
accurate witha amaxim~w.ierror. with respect to the FEA values
of only 3,394,

1,33K,S,,,

The EJMA Standards do not habe an acceptance criterion for

beBiows lateral deflection, A limit i s necessary because the
pedomanee equations are based on srnall deflection theory,
For typical convolution geometry's, the f011o~vigligacceptance
has been used

Y snli and y bmr <.042(Ny -+ 2Lt !

1 94Error

Table 4

I<l,O

.--.

/ 4 , 0 13-3

PRESSURE STOPS
Pressure stops are sornetbnes used 10 support bellows rails
between the corners. By reducing the unsupported rail length,
they reduce beilows 1ongitudinalB bending stress and lateral
deflection, Becaa~sepressure stops limit the inward 0-9. outward
deflection o f the bellows, they must be designed resist the load
generated by the bellows, The load i s equal. to the presswe
times the effective bellows area. %f
the stops are equally spaced
between one another and the comers, the following equation
can be used to determine the load:

Verification Case Resulb

EJMA ACCEPTANCE CRlTERlA

The EJh4.A Standards give an acceptance criteria for evaluating

the pressure stress results, Based an the new xrzealgrodology

described above, the EJ1Zr&s"hacceptance cslts~iamay be revised
to the following:

6 N 1, set I",,

S,, and S7]1Sa5

70 determine the accwacy of this equation, a FEA model

was created using 4 node thin shell elements (6 DOF per node),
The ends asad edges of the model were completely fixed,

1fB;hetangent is fully supported against the pressure, set I&,= 0,

0,

Chiform pressure is applied on all of the inside surfaces, The

nodes at the center of

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Figure 9 --- FEA Model for Pressure Stop Loading

the rail were resnaked ina the U direction to represent xhe
presence 0%a pressure stop, The exaggerated deformed plotis
s h o w in Figure 9,'The model represents a rail with IN = 2 ingg,, q
= 2 in,: W = 4 , lit;--: 1 ins,t = 0-05 in,, L = 100 in,,andP = 15
psig, The total reaction force on the restrained nodes was 5410
Ibs, The equation for F,, gives a hree of 5250 Bbs, For this
example, the equation i s reasonably aecz~atefor predicting the
pressure slop Isad,

REFERENCES

[I] Standards of the Expansion Joint Manufacrurers Assoc., 8"

Edition, 2085 Addenda, Tarrytown, New York, 2005,
[2] Cssn~osLM2-95Software, Solid Works Carp, Concord,
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