This review aims to complement a milestone monograph by Singer et al. (2002, Buckling
ExperimentsExperimental Methods in Buckling of Thin-Walled Structures, Wiley, New
York). Practical aspects of load bearing capacity are discussed under the general umbrella of buckling. Plastic loads and burst pressures are included in addition to bifurcation and snap-through/collapse. The review concentrates on single and combined
static stability of conical shells, cylinders, and their bowed out counterpart (axial compression and/or external pressure). Closed toroidal shells and domed ends onto pressure
vessels subjected to internal and/or external pressures are also discussed. Domed ends
include: torispheres, toricones, spherical caps, hemispheres, and ellipsoids. Most experiments have been carried in metals (mild steel, stainless steel, aluminum); however,
details about hybrids (copper-steel-copper) and shells manufactured from carbon/glass
fibers are included in the review. The existing concerns about geometric imperfections,
uneven wall thickness, and influence of boundary conditions feature in reviewed
research. They are supplemented by topics like imperfections in axial length of cylinders,
imperfect load application, or erosion of the wall thickness. The latter topic tends to be
more and more relevant due to ageing of vessels. While most experimentation has taken
place on laboratory models, a small number of tests on full-scale models are also referenced. [DOI: 10.1115/1.4026067]
Keywords: cones, ellipsoids, hemispheres, toricones, torispheres, toroids, external, internal pressure, buckling, plastic load, burst pressure
Introduction
tion: why, despite a great research effort, has the scientific community failed to develop procedures for shell design that are not
based on empirical data, i.e., on lower-bound followed by a
knock-down factor? They do not provide a definitive answer to
this dilemma which still exists more than ten years on. Instead
they propose a number of procedures aiming at improvement of
over-conservativeness of the lower-bound design philosophy for
the case of axially compressed cylinders (including FRP cylinders). In a review of the buckling resistance of thin and slender
structures typically found in nuclear industry, Ref. [26], back in
1984, categorized vessel related components, prone to buckling,
as: (i) stiff (buckling in plastic range), (ii) medium (elastic/plastic
buckling), and (iii) soft (elastic buckling). The criterion used here
was the ratio, REY, of elastic bifurcation-to-first yield load. For
REY 5 the component was deemed to be stiff. For REY 0:2,
structure was classified as soft. In this context, the results of 42
experimental buckling tests have been compared with computed
predictions of buckling. The tests were on metallic torispherical
and elliptical heads, cylinders under: shear, axial compression or
external pressure, spherical caps, spheres, and stiffened/unstiffened baffles. Scatter of results is provided here as Table 1 (from
Ref. [26]). Table 1 shows the difference between tests and numerical predictions of buckling together with the number of tests carried out. It is seen here that the range of errors varies from 30%
to 50%. The discrepancies between experimental and computed
values have been attributed to: (i) specimen geometry, (ii) boundary conditions, and (iii) material data. It was also noted that in
some cases the buckling was difficult to observe experimentally
and it was subjective (internally pressurized domes; for example).
Progress has been made in assessing the issues leading to big discrepancies between test data and theory since the publication of
Ref. [26]. Testing methods, for example, have improved and they
have been more focused [2730]. It is true to say that buckling
experiments are now better instrumented than in the past; for
example, in Refs. [27,28,3033]. Equally, more rigorous
C 2014 by ASME
Copyright V
Number of tests
3
5
5
7
6
6
5
5
Cylindrical Shells
Fig. 1
2.2 Axial Compression. Buckling strength of axially compressed cylindrical shells still attracts sizeable amount of research.
One specific topic has been devoted to buckling of variable length
cylinders under axial compression, as sketched in Fig. 1. When
two or more cylindrical segments form a prime load bearing structure then the interaction between two neighboring segments
become critical when the load is axial compression. The possibility of buckling of either one or both segments complicates the segment-to-segment interaction. Typical application exists in
aerospace where the gap between segments is filled by shimming
[56]. Once axial compression is applied to two segments where
there is a variable gap between them, then the uneven load results.
Diminishing axial gaps result in a variable length of hoop contact
between two cylinders and in localized plastic deformations.
These local effects at the imperfect end of the cylinder can propagate along the shells length. They in turn can trigger asymmetric
bifurcation buckling or collapse, and as such they can pose design
limitations. One aspect of this problem was studied in Ref. [57].
Cylinders with sinusoidal waviness of axial length were subjected
to axial compression by a rigid disk moving vertically. Numerical
results have highlighted a complicated nature of the interaction
between the plate and imperfect cylinder. A big drop in buckling
strength has been obtained for relatively small amplitude of waviness in length. In Ref. [58], 18 mild steel cylinders with the
length-to-radius ratio, L/R 2.4 and with the radius-to-wall thickness ratio, R/t 185 were collapsed by axial compression. Cylinders had variable length at one end of the sinusoidal profile. The
amplitude-of-axial-waviness-to-wall thickness ratio, 2A/t, was
varied between 0.05 and 1.0. Experimental results show that buckling strength strongly depends on the axial amplitude of imperfection (see Fig. 2). Average imperfect cylinders, with 2A/t 1.0, are
able to support 49% of experimental buckling load obtained for
geometrically perfect model. The largest sensitivity of buckling
strength was associated with small amplitudes of axial length. For
example, for axial length imperfection amounting to 25% of wall
thickness the buckling strength was reduced by 40%. It appears
that the number of sinusoidal waves in the imperfection profile
plays a secondary role, i.e., its role in reducing the buckling
strength is not a dominant factor. The paper provides experimental
details and comparisons with numerical results based on the FE
analyses.
Applied Mechanics Reviews
Fig. 4 Load carrying capacity of equivalent barrels as a function of barrelling, D/Ro. Photographs of tested models at a, b, c,
and d.
Fig. 3 Combined stability plot for cylindrical shell (axial compression, F, versus external pressure, p) [67]
loads. While these tests were within elastic domain, the concerns
were raised about the retest data. In view of this, Ref. [61] provides two sets of test data, i.e., single test and retest buckling
results. In a separate study, the influence of the thermal insulation
layer onto buckling performance of cantilevered cylindrical shell
is reported in Ref. [62]. This is both an experimental and numerical study. Vacuum induced buckling tests of small steel cylinders
are reported in Refs. [63,64]. Models were mass manufactured
industrial containers for storage of paint. Initial geometry of cylinders generators was carefully measured and the loading
amounted to hydrostatic external pressure. The content of Ref.
[65] is in many respects unique. It provides insights into load carrying capacity of on land vertical storage tanks, usually found in
the petroleum industry, under buckling conditions. Four steel
tanks with volume capacity ranging from 1000 m3 to 65,000 m3
(with radii between 5 m and 35 m) were in situ measured for geometry (geometrical imperfections), and then buckled by external
pressure (through the application of internal vacuum). The paper
provides a wealth of practical information including: design code
estimates, implications of quality of manufacturing, knock down
factors, and FE analyses (including axial compression generated
by roof-loading).
2.3.2 Bowed-out Cylinders. Buckling strength of axially compressed bowed out cylindrical shell can be larger than buckling
load of mass equivalent cylinder, as shown in Fig. 3 (with details
in Refs [66,67]). At the same time, barrels are more efficient in
supporting external pressure. This idea has been explored in Refs.
[6873] for underwater applications. Earlier background to the
above idea can be found in Refs [74,75]. It is seen in Fig. 4 that
external hydrostatic pressure increases with the amount of outward barrelling; it reaches maximum and then it drops when the
shell becomes the outer half of a toroid. A number of mild steel
models have been machined to test numerical predictions. All
models had the same mass as the reference cylinder and they had
integral flanges at both ends. Each shell after over machining was
stress relieved. Wall thickness and shape have been measured
prior to testing. The diameter of the tested shells was about
200 mm, their length varied from 75 to 100 mm in order to secure
the constant mass while the wall thickness was nominally 3.0 mm.
Thick flat plates were attached to tested models, which were then
filled with oil and vented to the atmosphere. Models were
010803-4 / Vol. 66, JANUARY 2014
1
(1)
Ro D
0:5 Lo n3
where Ro is a barrels radius at top/bottom ends; D is the amount
of barrelling at the equator.
Parameters n1, n2, and n3, which strongly influencing the barrels meridian, were chosen as optimization variables. Simulated
annealing, SA, was utilized in the search for the optimal shape
leading to the maximum of buckling pressure under the equality
condition imposed on masses, m, of the cylinder and barrel, i.e.,
mcyl mbarrel.
A section through the design space is plotted in Fig. 5. It is seen
here that a significant increase in buckling pressure above the cylinders one was predicted. Detailed calculations were performed
for the reference cylindrical geometry given by Lo/Ro 1.0 and
Transactions of the ASME
Fig. 6 Plot of the cost function versus design vector components n1 5 n2. Also, photograph of two tested barrels E1 and
E1a [76].
Conical Shells
Their apex half-angle was 40 deg. Under single incremental loading, they failed by bifurcation with a number of hoop waves at the
conecylinder junction. Additional conecylinder model, this
time with a horizontal ring of 20 mm depth and placed at the junction, is tested in Ref. [98]. It appears that in all three references,
an exact bifurcation buckling was difficult to establish experimentally and remained a fairly subjective process. The above three
references provide detailed discussions around this subject.
3.3 Buckling Under Axial Compression. Recent tests are
reported in Refs. [99,100]. Five steel models fabricated from steel
sheets by cold rolling and longitudinal seam-welding were collapsed by quasi-static axial compression. The base diameter of all
models was 450 mm and the wall thickness varied between
0.7 mm and 0.9 mm. Heavy plates were attached at both ends to
simulate clamped boundary conditions. Models failed through the
formation of axisymmetric bulge at the small-radius end. The test
ultimate loads were normalized by Rankine limit load, and the ratio varied between 0.98 and 1.11. In addition, 40 aluminum cones
fabricated by spinning [100] were subjected to axial squashing
between platens. The base diameter varied between 256 mm and
304 mm with the wall thickness being between 0.625 mm and
1.45 mm. Although the main objective was to evaluate the energy
absorption and folding mechanisms on the post-collapse path, the
collapse loads are also reported. Results of the FE analyses for
some models are given, and the ratio of experimental collapse force
to the FE estimate, Fexp tl/Fnumerical, was between 0.17 and 0.75.
3.4 Combined Loading. It appears that there has been very
limited research into elasticplastic buckling performance of conical shells, under the action of combined loads. The previous
research effort has primarily been limited to buckling by external
hydrostatic pressure which in fact corresponds to combined loading due to axial compression resulting from pressure action on
top/bottom flanges, e.g., Refs. [86,88,89,91].
In order to gain a better understanding of buckling of cones
under combined loading, two series of buckling tests on laboratory size steel cones have recently been carried out in Liverpool.
Models were CNC-machined and all of them had integral top and
bottom flanges. They were subjected to: (i) axial compression, (ii)
external radial pressure, or (iii) any combination of pressure and
axial compression. Nominal dimensions of the first set of models,
13 in total with designated names C1, C13, were as follows: the
cone semiangle, b 26 deg; the ratio of the larger radius, r2, to
wall thickness, t, was r2/t 34.0; the wall thickness, t 3.0 mm.
Details about experimentation and related FE computations can
be found in Refs. [83,93,101106]. The second set of ten models
had the following geometry: b 14 deg; r2/t 54.0, and the wall
thickness, t 2.0 mm. Here, details about the experiments and the
FE results can be found in Refs. [107111]. Figure 10 shows two,
as manufactured models (b 26 deg in Fig. 10(a), and b 14 deg
in Fig. 10(b)). None of the models were stress relieved prior to
testing. Combined loading was applied to them using arrangement
shown in Fig. 10(c). Heavy top and bottom plates were attached
to each cone. Flanges were partially embedded into the plates in
order to secure clamped-clamped boundary conditions as realistic
as possible. Axial compression was applied through a ram
attached to the bottom plate and connected, through an internal
bar and pivoted coupler, to the top flange (see Refs. [83,101,102).
The whole arrangement seen in Fig. 10(c) was immersed in
350 mm 1000 mm pressure tank. External pressure in the tank
was controlled manually. At the same time, through a separate
pressure line, compressive force was applied via the ram. Various
loading scenarios were explored during experiments. Both sets of
models developed plastic straining before buckling. Hence different loading paths were explored first, and this included: (i) pressure preloading followed by incremental axial force loading, (ii)
axial force preloading followed by incremental radial pressure,
and (iii) proportional loading. References [102,104,106] discuss
Applied Mechanics Reviews
Fig. 11 Combined stability plots for b 5 26 deg cones [106]. Loading paths shown in Fig. 11(a) while configurations given by
the current Design Codes are superimposed in Fig. 11(b).
pressure for C11 also falls into the elasticplastic domain. The
same applies to cones C3/C4 subjected to pure axial compression.
While there is a substantial margin of safety against buckling
under a single incremental loading, the predictions of failures
inside of the elasticplastic domain can be of concern under
repeating loads. In the latter case, cones can fail through growth
of plastic strains if there is no shakedown. As mentioned earlier
the second set of experiments was carried out in order to verify
Transactions of the ASME
these unexpected results. It is seen in Fig. 12 that some of recommended configurations would buckle with plastic strains being
developed. This applies to cones CS1, CS6, CS7 (ASME, Ref.
[41]), and CS3/CS4 (ECCS, [42]). Buckling under pure lateral
pressure predicted by both codes remains elastic (CS2/CS5).
Hence the same observation about safety under repeating loads
remains true here for cones with code-based design loads falling
inside of the elasticplastic domain. Finally, views of buckled
cones C6 and CS1 are seen in Fig. 13.
Initial geometric imperfection in conical shells can lower the
buckling strength and there have been numerous studies addressing this topic. However, only a handful of tests have been carried
out on cones with deliberately built-in shape deviation from perfect geometry. It has been generally believed that inward dimpletype axisymmetric shape deviations from perfect geometry are the
most dangerous imperfections, i.e., leading to the largest reduction
of the buckling load. Reference [112], for example, examined the
influence of axisymmetric inward-bulge type shape imperfection
on the magnitude of buckling load (axial compression). The
imperfections were deliberately introduced during manufacturing
(by electro-deposition of copper). Thirty cones with the top end
radius-to-the wall-thickness ratio ranging from 181 to 1115 were
tested. The extreme sensitivity of the buckling load to initial
imperfections of the order of a fraction of the wall thickness was
confirmed experimentally. Imperfections found in real structures
are likely to have neither axisymmetric nor have the shape of
buckling mode but they rather occur locally. One needs to exert
high degree of skills when assessing the load carrying capacity of
complex structures prone to buckling. A three stage approach is
advocated in Ref. [113] for the assessment of imperfection sensitive real structure. The effect of localized dimple-type imperfections on the buckling strength of axially compressed cones was
addressed in Ref. [114]. The FE results showed that buckling load
of the cone with inward axisymmetric imperfection was nearly
equal to the buckling load of local imperfections which extended
60 deg or more around the circumference. Twenty high quality epoxy conical shells were buckled in Ref. [115] by axial compression. The prime objective here was to develop experimental
knock-down factor against buckling. The paper also contains data
on axially compressed imperfect cylinders (built-in inward dimple). Recent numerical results given in Ref. [110] show that outward dimple-type shape distortion can be as bad as the
corresponding inward dimple. This directly contradicts the long
standing view that the inward shape imperfections constitute the
worst case. A subsequent study [116] considered geometrically
imperfect conical shells subjected to axial compression, external
pressure, or simultaneous action of both loads. Axisymmetric
shape imperfection was assumed to be an inward dimple, outward
dimple, or coexisting inward and outward dimples. The profile of
inward bulge was described by (see Fig. 14)
dz
8
>
>
<0
p
>
>
: di cos3
z zi
bA
9
bA >
>
2 =
bA >
;
jz zi j >
2
jz zi j
(2)
Fig. 14 Geometry of inward, axisymmetric dimple imperfection
[116]
Fig. 15 The worst interactive stability plots for different imperfection profiles (a). Collapsed shapes at points a, b, and c [116].
4.1 Hemispheres, Torispheres, and Toricones. End closures onto cylindrical vessels can take different shape forms ranging from flat plates to domed ends. The latter can include
spherical caps, hemispherical, ellipsoidal, torispherical or toriconical shapes. These shells also find way into other specialized
applications, e.g., large outer space mirrors. When the loading is
such that the internal stress is dominated by membrane stress
resultants and their associated, relatively high stretching stiffness
then the load carrying capacity becomes very efficient. In doubly
curved ends, the curvature of a shells mid-surface, together with
the high ratio of stretching to bending stiffness, generally leads to
a nonlinear interaction of membrane and bending effects. In cases
like that, the load carrying capacity of domed ends strongly
depends on their geometry, boundary conditions, material
010803-10 / Vol. 66, JANUARY 2014
behavior, type of applied load and the presence, or absence, of initial geometric imperfections. Static stability of domed ends has
been researched for decades both theoretically and experimentally, e.g., Ref. [120]. Review of past efforts in this area can be
found, for example, in Refs [7,121]. It is worth noting here that
the first tests on externally pressurized spherical caps were at the
end of the 19th century. Buckling tests on domed ends of other
shapes have continued until today and they were driven by variety
of reasons. For example, in view of raised concerns that aluminum
caps tested in Ref. [122] had the base diameter only between
20 mm and 50 mm, it was decided to re-examine the sudden drop
in buckling strength around the shallowness parameter k, k 4.0,
1=4
where k 231 t2 H=t1=2 (see Fig. 16 for notation). Six
mild steel caps with 200 mm diameter were carefully machined
from a billet. Each model had an integral heavy base ring, and
joining arrangement of the shell with base ring is shown in
Fig. 16. Three rings were designed to fail elastically and the
remaining three to fail within the elasticplastic range. Six test
points are superimposed in Fig. 16 on the original 1963 test data
by Krenzke and Kiernan. It is seen that indeed there is a minimum
of the load carrying capacity for k 4.0, irrespective whether it is
in the elastic or elasticplastic regime. Further details are available in Ref. [123]. An interesting piece of experimentation is
reported in Ref. [124]. Spherical caps manufactured from brass
with the wall thickness, t 0.4 mm, were subjected to outward radial load applied at the base of the cap. Experimental buckling
loads compared favorably with the theory provided.
An empirical approach to design of externally pressurized
hemispheres, adopted by British Standards Institutions BSI 5500
(now PD 5500), has been reviewed in Ref. [24]. The paper
addresses elastic and elasticplastic buckling. It points to the most
consistent safety factor over the experimental data, together with
a definition of allowable shape that includes both overall shape
allowance and a local defect parameter. Extension of PD 5500 to
externally pressurized torispheres triggered concerns about the
safety factor for sharp knuckle torispheres. Experimental results
of Ref. [125] demonstrate the kind of issues (see Fig. 17). It is
seen here that several test points plot below the lower bound curve
to all previously known experimental points, i.e., domes 1A, 1C,
4A, 4C, 7A, and 7C (see Table 2 for model descriptions). While
domes 1A and 1C are outside the stipulated lower limit on
r/D 0.06, it is the remaining heads tested at Brown University,
which surprisingly fell below the PD 5500 design curve (after
being multiplied by the 1.5 safety factor) which raised the concern
about the universality of the proposed experimental-lower-bound.
In view of these findings, it has transpired there was not much
Transactions of the ASME
Fig. 16 Plot of buckling load versus shallowness parameter, k. Also, view of collapsed cap and joining arrangements between the cap and integral base flange
(adapted from Ref. [123]).
Fig. 17 Safe and unsafe domains in PD 5500 code. Models 1A and 1C fall outside admissible geometry stipulated by PD 5500
(a). Test data for ten machined and two spun torispheres is plotted in (b) (pe 1:21Et 2 =Rs2 and pyss 2ryp t=Rs ) adapted from
Ref. [138].
Table 2 Geometry, material properties, collapse pressures, and parameters K and D for externally pressurized torispheres
E
Dome
r/D
Rs/D
Rs/t
L/D
(GPa)
1
1A
1C
4A
4C
7A
7C
P2/1
P2/2
P2/3
P2/4
P4A/1
P4A/2
0.059
0.0427
0.0427
0.0492
0.0492
0.0501
0.0501
0.060
0.058
0.058
0.059
0.060
0.062
1.01
0.749
0.749
1.235
1.235
0.989
0.989
1.05
1.05
1.03
1.04
0.775
0.764
563.64
128.99
126.09
61.47
61.47
45.189
45.189
143.99
148.60
146.00
148.60
83.0
83.0
0.37
0.20
0.20
0.33
0.33
0.37
0.37
0.05
0.05
0.05
0.05
0.09
0.09
207.0
192.4
207.0
192.4
207.0
192.4
207.0
208.0
208.0
208.0
208.0
212.0
212.0
ryp
pexp tl
(MPa)
370.0
220.4
435.2
243.6
365.4
243.6
365.4
430.0
430.0
430.0
430.0
426.0
426.0
0.128
0.662
1.172
3.862
5.655
5.793
7.586
1.71
1.78
1.78
1.67
4.65
4.62
Ref.
0.643
4.387
2.445
8.329
5.974
11.33
8.126
2.178
2.110
2.148
2.110
3.887
3.887
0.105
0.173
0.182
0.522
0.510
0.576
0.503
0.307
0.330
0.324
0.309
0.485
0.482
[120]
[125]
[125]
[125]
[125]
[125]
[125]
[128]
[128]
[128]
[128]
[127]
[127]
Fig. 20 Female molding tool after the first ply being draped. Also, view of hemisphere after the
collapse test.
Fig. 21 Pattern of distorted fibers after draping (a). One quarter of draped fabric superimposed
on the FE grid (b) [151].
r/D
T1
T1a
T2
T2a
T3
T3a
T4
T4a
0.2
0.2
0.1
0.1
0.05
0.05
0.0
0.0
pfailure
numerical
failure
pdesign
(MPa)
4.38
4.35
4.14
4.10
3.86
3.86
4.14
4.14
3.95
3.97
3.52
3.50
3.68
3.42
4.03
3.99
pfailure
exp tl
pfailure
numerical
6.39
6.39
5.20
5.20
4.55
4.55
5.16
5.16
1.11
1.10
1.18
1.17
1.05
1.13
1.03
1.04
Fig. 22 View of cone T4 as machined (a), and after collapse (b). Buckled toricones T2 and T2a
are seen in (c) and (d). External pressure in all cases.
Fig. 23 View of collapsed ellipsoidal shells (adapted from Ref. [159]). External pressure.
material. Views of buckled toricones are provided in Fig. 22. Reference [156] provides design equations for elastic buckling pressures derived from parametric studies, and these are extended to
plastic region as well. According to Reference [156], plastic buckling pressure of a toricone, ppl
toricone , can be approximated by the
following expression:
el
pfailure
design 0:5po 0:4ptoricone
(3)
(4)
and D is given by
p
D D 2r cosb 1 2 rt sinb
(5)
The quantity, po is referred to as the yield pressure, and it corresponds to the pressure which causes the spread of plastic strains
anywhere in the shell reaching half of the wall thickness. The values of, po, for different values of (r/D), the yield point of material,
ryp, Youngs modulus, E, and the (D/t)-ratio can be read from
design diagram. When read from Fig. 6 in Ref. [156] these values
are: 4.95 MPa, 2.81 MPa, 2.25 MPa, 2.03 MPa for models T1/T1a,
T2/T2a, T3/T3a, T4/T4a, respectively. The resulting failure pressures are given in column 5 of Table 3. All estimated values are
significantly higher, ranging from 18 to 47%, than the test data.
However, it needs to be said that design the equations, Eqs.
(3)(4), have been obtained for geometrically perfect shells, elastic perfectly plastic modeling of material, and for cone/toricones
being supported by cylindrical shell unlike here [157] where the
heavy base ring simulated clamped boundary conditions. Furthermore, reading values of, po, from a nomogram was not accurate.
However, the tendency of buckling pressure variation with the
knuckle size was similar between the Eqs. (3)(4) and the current
test data.
4.2 Ellipsoids. Elliptical shells of revolution can be used in
specialized applications, e.g., in pressure hulls for rescue-type
submersibles. Early test data is available in Refs. [158,159] where
two prolate ellipsoids, machined from 7075-T6 aluminum, were
collapsed under incremental external pressure (see Fig. 23) for
their view after collapse. The semiaxes were B 75 mm and
A 25 mm, while the wall thickness was 0.76 mm. Despite
010803-14 / Vol. 66, JANUARY 2014
different arrangements for boundary conditions around the equator, the collapse pressures differ only by about 10%. Results of the
buckling tests on an additional 33 machined epoxy resin models
together with the underlining theory are available in Ref. [160].
Elliptical shells of revolution can also be used to close the ends of
externally pressurized vessels, with typical applications in the
submersibles and space vehicle industry. Details about a recent
numerical and experimental study into buckling of steel ellipsoidal domes loaded by static external pressure can be found in Refs.
[77,161,162]. A range of geometries and thicknesses of domes
was examined, as was the influence of different boundary conditions. Shells were examined on the basis of having the same mass.
This meant that all shells were analyzed on a like for like basis,
and as such, each domes performance was easily quantified. Numerical analyses of both perfect and imperfect shells were carried
out. Two kinds of imperfections were considered: deterministic
imperfections derived from measured dimensions and eigenmode
imperfections. The main focus was on prolate domes, i.e., those
taller than a hemisphere of the same radius (Fig. 24). Numerical
predictions were confirmed by pressurizing six laboratory scale
prolate domes to destruction. Three current design codes summarized in these studies included: ASME VIII, PD5500, and the
ECCS. At present, prolate domes are not included in the three
codes. The method of calculating design pressures was outlined
and recommendations were made for the possible inclusion of
prolate ellipsoids into the codes. Currently allowed ellipsoids
(right of hemisphere) and suggested inclusion of prolate domes
(left of hemisphere) are depicted in Fig. 24. All domes in this figure have the same mass. Points (t1, t2, t3) are experimental points
(two tests per point). View of three nominally identical pairs of
prolate ellipsoids after testing is shown in Fig. 24. The ratio A/B
was 0.8, 0.65 and 0.5 for ellipsoids t1, t2, and t3, respectively. It is
also worth mentioning that the new European design rules for
externally pressurized vessels, EN 1993-1-6/Eurocode3, Part 1.6,
Refs. [163,164], do not contain prolate ellipsoidal shells. Oblate
ellipsoids, especially with (B/A)-ratio of two, have been frequently used as closures on cylindrical vessels. Oblate ellipsoids
with other (A/B)-ratios have not been widely used. The same
applies to domed ends whose generators were subject of structural
optimization. References [165,166] are two examples where the
shape of the meridian was searched for the best performance and
the optimum was subsequently subject of experimental verification. The latter reference examined the performance of externally
pressurized ellipsoids through the formal optimization process. In
this study, the highest buckling load was to be found within a
range of geometries of generalized ellipsoidal domes loaded by
Transactions of the ASME
Fig. 24 Currently allowed and proposed ellipsoids (a), prolate and oblate geometries sketched in (b), (c), and view of three
pairs of elliptical domes after tests (d)
external pressure. Generalized ellipsoids are a variation of standard ellipsoids in that the exponents used to size the dome are variables. A generalized ellipse is of the form
x v1 y v2
1
(6)
A
B
where
The adaptive Tabu search method was employed to determine values of v1 and v2, which give the maximum pressure resistance of
ellipsoidal domed ends. The results of the Tabu search are shown
in Fig. 25. Also shown in Fig. 25 are the failure pressures for
standard ellipsoids (i.e., v1 v2 2) of the same material, boundary conditions and mass. The optimum shell corresponds to point
a in Fig. 25 and has geometry of v* (1.92857, 1.57937, 1.4).
The optimal dome is 20% stronger than the reference hemisphere,
and has a failure pressure of pmax 12.84 MPa, mode of failure is
axisymmetric collapse.
To confirm numerical results obtained, four geometries of the
dome were machined from a mild steel billet (global optimum
plus further three geometries). The geometries of dome machined
correspond to points a, b, c, and d in Fig. 25, and their
nominal dimensions are given in Ref. [166]. All ellipsoids had the
same mass. Domes were machined in pairs, to demonstrate repeatability of the experiment and also act as a safeguard should one of
the pair be damaged, e.g., during manufacture. The domes were
machined with integral flanges in order to attach them to a base
plate for testing, and also to make sure that no radial movement of
the base was allowed during testing. Before testing, domes were
carefully measured for any variations in shape and thickness
details are in Refs. [166,167].
The experimental failure pressures of all the domes tested are
listed in Table 4. Also given are numerical predictions made using
BOSOR5 based on average thickness. The numerical results are
normalized by the experimental pressures and shown in parentheses. The numerical predictions are all within eight percentage of
the experimental values.
It is worth noting here that structural optimization of pressure
vessel components subject to buckling constraints poses multifaceted challenge. At the structural analysis level, significant insight
is needed into the effects of, for example, the effects of initial geometric imperfections, nonlinear preloading, boundary conditions,
or follower-type loading on the type and magnitude of buckling.
At the optimization level, there is usually very little knowledge
about the nature of design space. For the two cases discussed in
the case of ellipsoids the design space proved to be nonconvex. In
situations like these the use of zero-order approach appears to be a
very efficient approach (Tabu search in this case). A reliable
(7)
where S is surface area and was calculated by integrating numerically. This condition means that taller, prolate shells will have a
thinner wall due to their larger surface area. Conversely, shallow,
oblate domes will be thicker than the reference hemisphere. In all
cases, the shell wall thickness was kept constant as one moved
along the meridian.
The modes of failure considered here were bifurcation buckling, pbif, and axisymmetric collapse, pcoll. The lower of these two
failure loads was taken to be the critical failure load, pcr.
The optimization problem can be formally expressed as
popt v max pcr v1 ; v2 ; v3
(8)
(9)
1:5 v2 2:5
(10)
0:3 v3 4:0
(11)
(12)
v3 A=B
(13)
v v 1 ; v 2 ; v 3
(14)
Fig. 25 Failure pressures of optimized generalized ellipsoids. Also shown is the failure of standard ellipsoids (m1 5 m 2 5 2.0).
Points a, b, c, and d denote experiments (two tests per point) [166].
a1
a2
c1
c2
b1
b2
d1
d2
pexptl (MPa)
pnumerical (MPa)
13.24
13.46
7.98
8.14
10.21
10.14
5.07
5.07
12.88 (0.97)
12.90 (0.96)
8.18 (1.03)
7.98 (0.98)
9.77 (0.96)
9.69 (0.96)
5.47 (1.08)
5.39 (1.06)
Fig. 27 Two spun halves prior to welding into TS1. Toroids TS1 and TS2 after collapse [177].
the inside of shells was open to the atmosphere during the application of external pressure. The aim here was to avoid an
implosion type collapse of shells. The external pressure was
applied at Dp 0.04 MPa. The end of the load bearing capacity
was associated with a sudden loud bang, large outflow of oil
through the vent, and big drop in pressure. Photographs of shells
after removal from the pressure tank are depicted in Fig. 27 and
Fig. 28. Experimental collapse pressures are given in Table 5 together with numerical estimates based various modeling assumptions. It is seen that a reasonable agreement has been obtained
between experimental failure pressures and numerically predicted
values. The ratio of (pexp tl/pnum) varies between 0.82 and 1.0
while results, which have so far been published in the literature,
oscillate between 0.40 and 1.40.
5
Fig. 28 View of stainless steel toroidal shell, TE1 being lowered to pressure tank for testing (a), and the model after collapse (b) [177]
Table 5 Externally pressurised steel toroids: comparison
of experimental and numerical pressures for different
numerical models (1 5 nominal, 2 5 average, 3 5 min, 4 5 max,
5 5 variable)
pnum (MPa)
TS1
TS2
TE1
pexpt(MPa)
9.44(0)
7.10(0)
8.68(0)
8.10(0)
5.66(0)
8.68(0)
5.68(0)
3.68(0)
7.18(0)
9.40(0)
6.64(0)
9.64(0)
8.40(c)
5.20(c)
7.48(0)
8.40
4.28
7.24
1:71
R
1:13 0:0486 ryp=E
r=t2:34
r tr
(15)
5.1 Buckling. Domed ends onto internally pressurized cylinders appear in much wider engineering applications than externally pressurized counterparts. Their safe and efficient design has
attracted a significantly larger amount of research effort since, on
one hand, the thinner heads are prone to buckling, and the transition region between bifurcation buckling and axisymmetric yielding is not well defined; however, it is of practical relevance, on
the other hand. In addition, studies to develop inelastic and limit
analyses have also been carried out. Previous work in this area
has been well documented and regularly reviewed. A good
source of relevant information can be found in Refs.
[2,7,20,22,27,181188].
An approximate expression for the limit pressure corresponding
to appreciable plastic deformations in internally pressurized torispheres can be found in Ref. [189]. Experimental verification of
plastic limit analysis for ten torispherical and for three toriconical
shells was discussed in Ref. [190]. Experimental work into the
failure of 12 torispherical ends subjected to internal pressure is
reported in Ref. [191]. All models were manufactured from aluminum alloy and some of them failed through asymmetric bifurcation buckling while the thicker models failed by plastic
deformation. Results of a parametric study into elastic buckling,
and first yielding, for torispherical shells were studied in Ref.
[181]. Comparison of test and theory for asymmetric elasticplastic bifurcation buckling of torispheres is available in Ref. [185].
JANUARY 2014, Vol. 66 / 010803-17
Fig. 29 Comparison of computed plastic load pC1 with experimental values. Also, plot of experimental burst pressures. View
of burst models K1, K2, and K6, adapted from Ref. [201].
Fig. 30 History of plastic strains growth versus number of pressure cycles in steel
torisphere T8 (a). Also views of burst oblate ellipsoidal models: (b) mild steel, and
(c) aluminum (adapted from Ref. [206,207]).
aluminum alloy. Shakedown was based here on kinematic strainhardening, and ellipsoidal model, EAL1, after the burst is depicted
in Fig. 30. It appears appropriate here to mention the availability
of 1904 seminal paper by M. T. Huber, which has been translated
into English in 2004 as Ref. [211]. This work has formed the basis
for the HuberMises yield criterion.
While the role of plastic loads for internally pressurized heads
is still being researched, it is the burst pressure which is of greater
value from a practical point of view as it gives an indication of the
margin of safety for a single incremental loading. This is an important quantity, especially, at a design stage or at an emergency
situation.
5.3 Burst Pressure. A number of studies which are relevant
to the issue of burst pressure are available in the literature, and a
brief summary can be found in Ref. [212]. A procedure for numerical calculation of pressure at tensile plastic instability for internally pressurized axisymmetric pressure vessels has been
developed in Refs. [213215]. The proposed pressure is to be an
upper bound to the burst pressure that could be achieved in real
vessels. While the failure mode caused by plastic instability has
been studied analytically and experimentally, it is excessive plastic deformation which is a more probable mode of failure than
bursting due to plastic instability (see Ref. [216]). A recent theoretical and experimental study into burst of internally pressurized
domes can be found in Ref. [212]. The burst pressure is based on
excessive plastic deformation rather than on plastic instability. It
is postulated to use the true plastic strain, eup , corresponding to the
ultimate tensile strength, UTS, for computing the magnitude of
burst pressure. One needs not only the magnitude of plastic strain
but also a place where this strain is to be attained. Based on the
above criterion for admissible magnitude of plastic strain, it is further postulated to define the burst pressure as follows: pburst is the
pressure at which the equivalent plastic strain, PEQQ, reaches the
ultimate plastic strain, eup , anywhere at the mid-surface of a structure. A series of calculations have been performed for mild steel
shallow spherical caps, tested previously for buckling, Ref. [123],
and for torispherical heads tested previously for plastic loads, Ref.
[201]. The latter were from mild steel. In addition, four
JANUARY 2014, Vol. 66 / 010803-19
torispheres were freshly machined from aluminum alloy AA6061T1 to complement the series of tests. Hence, burst tests were carried out on: six steel and four aluminum torispheres and six spherical caps. Computed burst pressures for steel spherical caps were
between 21.1 and 4.9% below experimental values. At the
same time, the errors between computed plastic instability pressures and the experiments were between 35.1 and 51.8% (overestimated experimental results). For steel torispheres the
respective ranges of errors were: [12.1%, 32.4%] and
[17.6%, 42.8%]. In aluminum torispheres the ranges were:
[0.4%, 14.0] and [12.7%, 20.8%]. It is seen here that the
magnitudes of computed plastic instability pressures were above
experimental values for all tested models. Derivation of plastic
instability load for internally pressurized stainless steel toroid,
followed by burst tests of two models, can be found in
Refs. [217,218]. Seventeen 45 liter carbon steel toroidal tanks
were burst-tested during qualifying procedure for the anticipated
LPG usage [219,220]. Water was the pressurization media. Tanks
burst when volume increased by about 11%, and the standard
deviation on average burst pressure of 8.56 MPa was about
0.220 MPa. The FE assessment of structural integrity was based
on monitoring the maximum deflections at the apex and at outer
equatorial plane. Other relevant work in this area can be found in
Refs. [221,222].
Closure/Conclusions
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Jan Bachut received his MS.c. in Physics in 1971 (Jagiellonian University, Krakow, Poland), Ph.D. in 1980,
and DS.c. in 1996. The latter two were in Mechanics and both from Cracow University of Technology
(CUT). For nearly a decade he worked at the Institute of Physics, CUT and then for more than 30 years he
taught and performed research at Mechanical Engineering, The University of Liverpool, UK. Currently he
holds the Chair in Mechanics at the Institute of Physics, CUT, and is Visiting Academic at the University of
Manchester Aerospace Research Institute, UK. He has published more than 150 papers in reviewed scientific
journals and proceedings and serves on Editorial Boards of Engineering Optimization and Technical Transactions journals. Recently he was co-chairman of Euromech Colloquium in Liverpool and CISM course in
Udineboth devoted to various aspects of structural optimization. He is a full member of the ECCS Technical Working Group 8.4 on Buckling of Shells, and has worked for Sub-Committee on Design Methods PVE/
5British Standards Institution. His research interests include buckling of shells, integrity of pressure vessels, and structural optimization of components aimed at on land, in the sea and in the air applications.