r

StressAnalysisof ConicalPipe-reducers
M A Rahman,Non-member
G M Zulfikar Ali, Non-member
Md R Khan,'Non-member
Md W Uddin. Non-member

This paper deals with the stressesin the conical pipe reducers, usedfor connecting pipes of unequql
diameters,under unifurm internal pressure. Computerprogranxfor stressanalysis of general composite
shells,with necessarymodifications,has beenusedfor thepresentanalysis.In this analysis,governingnon-
tinear equations-foraxisymmetric deformation af conical reducersare solved by the method of multisegment
integration, developedby Kalnins and Lestingi. The discrepancybetween the linear anri the non-linear
theoriesin predicting the stressesin the reducersis discussedin the anaiysis. The effict of variation of the
apex angle and the thicknessratio of the conical reducerson :he stressdistribution is also discussedin this
paper.

Ke.ywords.'Stressanalysls.Pipes,Conrcal reducers

NOTATION y : semi-apexangleof the reducer

C,D extensional rigidity, Eh; bendingrigidity €x, Go : middlesurfacestrains
E h 3 / [ t 2 ( -r u ' ) J
I - - €x, €0 : e x Ehxe/PR', eg Ehx./ PR"
7,D (1-v') xs/r, t/\12 P T2 R (t -v2)i
6rr Oa : circumferentialand meridional stressesre-
E,v Young's modulus. Foisson's ratio, respec- spectlvely
tively
(rci, oco, ; circumf"erentialand meridional stressesat the
h,7 reducerwall thickness,R/lz
oai, oao innerand outerfibres,respectively"
I:1,V radial and axial componentsof stressresul-
0e, $ : anglebetweenaxis of symmetryand normal
tants,respectively
to undeformed and deformed middle sur-
H,V H/PR, V/PR faces,respectiveli
kg, kt circumferential and meridional curvature INTR.ODUCTION
changes,respectively
Stressesin the pipe reducers,used for connectingpipes of
-Ko,k, kg xe, kx xe unequaldiameters,are completely different from thosein the
Mg, M, circumferentialand meridional couple resul- pipesunderthe sameinternalpressure.It is, thus,esseritialto
tants,respectively analyzethe stressesin the reducersseparatelyfrom those rn
the pipes.Further,useof reducersalwaysinvolvesthe useof
fuIr, fuI* Me/PRh, Mx/PRh
flanges for their correciion with the pipes. These flanges
Nr, Ne rneridional and circumferential stressresul- alwaysintroduceadditionalstresses in the pipesas well as in
tants,respectively the transitionalreducerelements.The presentanalysisthus
investigatesthe stressesin the pipe reducers for varying
lrr, lge Nx/PR, Ne/PR
parameters"
P,F,N externalpressure,PlE, xe/R
It has been shownr'3-tr that the non-lineartheory of shells
R r ,R radii of the smaller and larger pipes respec- are essentialfor analyzingthe distributionof stressesin the
tively, connectedby the reducer pressurevesselproblems.This is due to the fact that, at the
f,}, lo . radial distanceof points on the undeformed junctions of two different segmentsof shells or at points
middle surfacefrom axis of symmetry,ro/xs havingsmall meridionalradiusof curvature,the lineartheory
U,W radial and axial displacements,respectively fails to accou'ntfor the pronouncedchangein curvatureand
consequently predictsunrealisticsolutions,This fact becomes
i,w uEh/PRz, wEhlPRz more evident at higher loading and for thinner shells3'4.
xri distancemeasuredalong meridian, x/xs Soluiionsare, thus, obtainedfor reducersof different thick-
Xs total meridional length of the reducermeas- nesses,using both linear and the non-lineartheoriesin the
ured from its apex. presentanalysis,so thattheshortcomingsof the lineartheories
- $, r1y*u in caseof reducersare verified and noted.
c[,p,r shell parameter,$1y
The multisegmentmethod of integration developedby
MA Rahman,GM ZulfikarAli, Md R Khan and Md W Uddin arewith
the Department of Mechanical Engineering, Bangladesh University of KalninsandLestingiris usedhereto solvethenon-linearshell
Enginecring and Technolopr, Dhaka, Bangladesh. equationsfor theconicalreducers,This multisegmentintegra-
This paper was receivedon November 7, 1996.Written discussionon the tion techniqueis a very powerful tool for handlingnonlinear
paperwill be receiveduntil January3l, 1998.
shellequationswhereboth the finite elementand finite differ-

Vol78, Novemher1997 t45

 ii -'
t .
techniques usually fail due to nonconvergence in the
:Td dM
ipration processof thesetechniquesin caseof boundary value = a cos Q (Me - Mx)/7 -
d;
6problems. This method can be used for shell meridian of any
length with discontinuity in siope or thickness where method s, F T' (r/ sino - tcos Q) (16)
like direct integration fails. The above mentioned governing equationsinclude approxi-
GOVERNING EQUATIONS mations of the Kirchoff hypothesis and other plausible as-
sumptions, like the middle surface strains are negiigible
Reissner's2nonlinear equations for axisymmetric deforma-
compared to unity, leading to the dropping of terms of the
tion of shellsof revolution, as modified by uddin3, is usedin order of hlR in the constitutive equations.However, these
this analysis.The governing equations are given under: assumptionsdo not introduce any significant error in the
u solutionsof most practical thin shell problems.
€0 = = (1)
f11
BOUNDARY CONDITIONS
0=00-F (2) For the generalcaseof axisymmetric deformationsof shells
Ee= (sinfu - sinQ)/Tu (3)
of revolution, it was shown3that the boundary conditions at
the edgesrequire specificationof :
I/'=FcotO+VsinS
{4) H o, i, fuI* or F, uno 7 or w (r7l|
e = e N, - vEe (s) considering both the larger and the snnallerdiametersof the
k. - M x / D * k w (6) reducer sufficiently large and connected to the reducers
through flanges, it is quite justified to assumethat both the
=
No
(tt = vE-)te (7) def orrned
Ue = D ( i e + v&r) (8)
a,=L*€-r (e)
r = L f o * H (10)
dw
-=Cx s i n Q- Z s i n f o (11)
ox
du
:-:-g cosQ- Zcosfo (r2)
ox
dB ;
fr=r, (13)
7,-unde
f orrned
dv d cosQO/T - FV)
dx (r4)
dH
-t'te)/7
a {tacosQ +F TsinQf (1s)
dx

Fig2(a) Side view of element of sheli In deformed and

undeformed state

1i
4.i, t l
t l
t l
I t

iu
Y

Fig 2(b)Elementof shellshowingstress resultantsand

Flg 1 Mlddlesurfaceof shell couples

146
IE(I) Journal - MC
ends of the reducer are fixed or clamped. Hence, conditions theoriesare shown in the samefigures. It should be mentioned
at both the larger and smaller ends of the reducerare specified here that a diameter reduction ratio of 0.5 is consideredin this
as analysis,iei = 1.0correspondsto the largerend of thereducer
il=A,9=0,w=0 ( 1 8 ) while x = 0.5 correspondsto the smaller end (Fig 3). From
SOLUTION the resultsas shown in Figs (4 - 8), it is evident that the linear
theory is very conservativein predicting the results. It is also
The same method of multisegment integration as used by
noted that the conservativenessin estimating the stresses,
Uddin3 for nonlinear analysis of pressure vessels has been
stressresultantsand the moment resultantsincreaseswith the
employedwith boundaryconditions given in equations(18)"
increaseof thinness. Uddin3 pointed out that for shells sub-
The program starts with an initial arbitrary load F and an jected
to internal pressurethis conservativenessof the linear
incremental load step A F, and then solves the nonlinear theory also increasedfor increasing values of loading parame-
governingequationforload F with apreassignedconvergence ters,although,for avoiding the crowding of too many results,
criterion. The load F is then increasedby the incremental load it is not shown in this analysis.However, it is observedthat
the prediction of nonlinear theory about the meridional stress
step A F and solution is then obtained for this new load,
through iteration, with solutions of immediate previous load resultants,Nr, ir higher than that of the linear theory, which
as initial values.If the solution fails to converge at any load F, is quite contrary to the observations in other composite shell
problems.
Rr/R=0.5 It should be pointed out here that the stressparametersare all
normalized in terms of the loading pararneter"As a result,
there is no variation of the normalized parameterswith the
loading for linear theory [Figs (4 - 8)].
The most interesting observation in the presentanalysisis the
effect of the apex angle on the predicted results. It can be
observedfrom the Figs (4 - 8) that the discrepancy between
the linear and the nonlinear theories in predicting the results
becomesmore prominent for reducers of higher apex angle
(90') than thobeof smaller apex angle (60').

Nonlrnear
--- Lrnear

Fig 3(a)Gonlcalreducer(parameters: R/]r= thickness ratio,

RrlR = reductionratio,1= seml-apexangleof the conical
reducer) f>
Rr/R-0.5 R/h= 300

X=0.30

l>
Fig 3(b) Parabolicreducer(parameters: R/lr= thlckness ra$o,
Rr,/R= reductionratiorr)
the load step is halved and the solution is again attempted.
In this way, nonlinear solutions are obtained at increased
values of the loading parameter upto the desired level of
loading.
RESULTS AND DISCUSSION x
In orderto point out the dgficienciesof the resultsof the linear Fig 4 Effectof apexangleand thicknessratlo on meridional
theories, the results of both the linear and the nonlinear bendingmomentsin the reducer

Vol78, November1997 147

 P/E= 3x 10-5
v =0.30

-c
E.
o_
lz o
b
tl
lb-
= tr-1
'+..t
"tr
t

rQr/ rhr r-- u?wn vn

c
E
o_
6
( > h
tl
r. o

Flg 5 Eltct of apex englc md thlckness ratlo on mcrldlona!

i
stresc resultantsIn thc rrducor Flg 7 Effectof apexangleand thicknessratio on meridional
stressesin the reducer
t,
This is becauseof the fact that the cone approachesto a plate
as the apex angle is increased,losing its membranestiffness^
n \
Consequently,conical reducerswith higher apex angle de-
\\\ \ forms substantially under load, resulting in noticeabledis-
\ \
crepanciesbetweenthe two theoriesin predicting the results.
t

\r\ Fig 4 shows the variation of the bending moments along the
sheli meridian. The presenceof bending moment, in effect,
shows the disturbancein the membrane solutions of the re-
ducer.In other words, the magnitudeof the bending momenr
P/E= 3x 10's \
is ameasureof the deviationfrom the characteristicmembrane
v = 0.30 behaviourof shells.The discrepancybetweenthe linear_and
Y=450 the nonlineartheoriesin predicting the solutions is observed
here to increasewith increasingthinnessand increasingapex
angle.
The meridional stressresultantsare shown in Fig 5. As an
exception,it is observedthat the linear theory predictslower
values of the stressresultantsin comparison to that of the
nonlineartheory,{uite contraryto the normal expectations.
The circumferentialstressresultantsare shown rn Fig 6. It is
clear from this figure that the linear theory overestimatesthe
results comparedto nonlinear theory. Further, it is observed
that this stressresultantincreasesas apexangleof the reducer
increasesand its maximum value occurs in a zone very close
to the flange at its larger end.
The variationsof the meridional stressesat the inner and the
outer surfacesalong the reducermeridian are shown in Fig 7.
.5 .6 .7 .B .9. 1.0
X The presenceof bending moments at and near the two fixed
Fig 6 Effect of aper angie and thickness ratio on circumferen- ends are responsiblefor the wavy distribution of the stresses
tial stress resultants in the reducer near the two ends. The maximum meridional stressin the

r48 IE(I) Journal - MC

reducer occurs at the inner face of its junction with the
larger-endflange and its value is about 5.2 times the mem-
branemendionalstressin a cylindrical shell of radiusfr and
thrckness&"
The circumferentialstressesat the inner and the outer surfaces c.
,\l
t\\
of thereducerareshownin Fig 8^Here also"it rsobservedthat oc
o_
\\l

the predictionof the stressesby the linear theor,vis mucll

higherthan that by the nonlineartheory. il

fb' P/E=3x10s
Observationfrom the stresscurves shown in Figs 7 and 8,
revealsthat the meridionalstressesat the rnnersurtace(oaii Fj/h= 300
rs the rnost critical stress.It is also seenthat the recluceris v-30
critically stressednearthe two ends. ..\
-,L

.25 .50 .75 1-00

Rahman'istudredthestresses in a paraLrolic
reducertFig t 3b)l X
subjectedto internalpressure.The result of the analysishas
Flg 10 Clrcumferentlal stressesfor a parabollcreducerlr
lc
shown that, for the samediameter reduction ratio (0.50) and
thickness ratio (300), the stresses in a parabolic reducer
are much lower in magnitude than that in a conical reducer
o
cl [Figs (9 and 10)] at the sameintensity of loading.From Fig 9,
_c
o
the maximum non-dimensionalmeridional stressat the inner
o:
o-
c0
surfaceis only 1.4 in caseof a parabolic reducer,whereasit
o
o
is as high as 2.6 in the identical conical reducer (Fig 7).
II
Similarly, the circumferential stressesare also of much
lb'
-5 smallermagnitudein a parabolicreducer(Fig 10) than that in
P / E= 3 x r,nu R / h= 3 0 0 an identical conical reducer(Fig 8).
v -- l- tr rwO
v=030 [
Comparing the conical reducerswith their counterpartpara-
bolic reducers, it is observed that the parabolic reducers are
far superior to their conical counterpartsin respectof stresses
in them forthe s:rmeinternalpressure.Of course,stressshould
not be the only factor in concluding the superiority of the
o parabolicreducersover their coniial counterparts.For exam-
ci
ple, factors like easeof fabrication and loss of energy by fluid
l:
\ flowing through them should also be taken into consideration
r C o
L in evaluatingthe ultimate superiority of one kind of reducer
l-) over the other.
ro CONCLUSIONS
It is concludedthat the nonlinear theory is essentialfor ana-
lyzing the stress problems of reducers, specially of thinner
reducers.In most of the cases,the linear theory fails to account
for the effect ofchange in curvatureand consequentlyover-
. 5 6 . 7 B . 9 1 . 0
x estimatesthe stressesdevelopedin the reducersunder uniform
Flg 8 Etfect gf apex angle and thlckness ratlo on clrcumferen- internal pressure.The pipe reducers are critically stressedat
tial stresses In the reducer and nearthe flange connectedendsbecauseofthe presenceof
the bending moments.An important observation of this work
is that the more the apex angle the more is the discrepancy
betweenthe linear and the nonlineartheoriesin predictingthe
results.The result of this analysishas also revealedthe fact
that, betweena conical and an identical paraboli.creducer,the
-C
CE. latter one can withstandmuch hither internal pressure.

t)
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tl

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al
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;
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150 IE(I) JournaX;*,1ilC