Minimum five
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
190
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
191
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
192
pressure drop in the bellow, leakages if any in the bellow. Bellow should come to
its original shape after removal of pressure.
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
193
bellows indicates motion extending into the plastic range, since material thickness
is taken very less in order to get higher flexibility.
Spring rate determination of a bellow becomes more critical as variation in
geometric parameters and bellow deforms in elastic range as well as plastic
range. Many times due to higher deflection taking place in piping length,
deformation stresses becomes very significant. But assuming the movement of
bellows deformation is within elastic limit, the axial theoretical spring rate can be
determined experimentally, which can be useful for the limit of axial deformations
of bellows.
A simple press type fixture is necessary for the spring rate test. Following
procedure can be used for test. The diagram is shown in figure 6.2.
1. The expansion bellow to be tested is placed in vertical position in the fixture
as shown in the figure 6.2. The bellow is held in place by means of
fastening clamps.
2. Measurement of the length of bellow should be feasible with fixed or free
scale at different loadings.
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
194
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
195
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
196
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
197
[B13]
principles are helpful for making robust product. They are system design through
innovations, parameter design, tolerance design, product design optimization,
process design optimization, statistical quality control etc.
6.8 Design of Experiments
In the present business scenario of globalization a revolution is taking place due
to customers higher expectations and breakneck technical changes are taking
place which are causing yesterdays realities as tomorrows irrelevancies. Quality,
reliability and durability are the primary factors in the customers buying decisions
in the present overall business revolution. The robust design of products is the
fundamental requirement of the customers.
Robust design means that the performance of the system is always acceptably
close to the ideal function of the system. A systematic and efficient way to meet
the challenge of developing a robust product is the statistical approach to the
optimization of the product and process design which was originally developed by
Sir Ronal A Fisher and later adapted by Genichi Taguchi for industrial products.
This work is an attempt towards optimization of various geometric parameters for
the spring rate of bellows. After that some tests are carried out and using results
some meaningful conclusions are drawn.
6.8.1 Taguchis philosophy:
All products have characteristics that describe their performance relative to
customer requirements or expectations. The quality of product is measured in
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
198
199
set of results are analyzed to determine the influential factors and preferred levels,
and weather increases or decreases of those levels will potentially leads to further
improvement. Basically this is an iterative process. Later on experiments typically
involve few factors at more than two levels to determine conditions of further
improvement.
6.8.5 The process of Design of Experiments DOE: [B13]
Following are the steps suggested for design of experiments by Taguchi
philosophy.
1. State the problem or area of concern:
A statement of problem should be critically framed so that will make clear and
concise description of the problem. Expansion joints are manufactured with
customized approach for individual application. The performance is mainly
depending on precise design and manufacturing methodology. The expansion
joint must perform expected flexibility while working. The flexibility of bellow is
depending on its material property and selection geometric parameters. The
initial theoretical axial spring rate can be evaluated from the parameters. The
spring rate of bellow must maintain consistently within limits, so performance is
assured. This testing will also help to reduce variation in manufacturing
procedure and quality will improve. The statement of the problem is framed as
Optimization of parameter design of expansion joints for the desired or
expected value of initial axial spring rate using Design of Experiment (DOE)
technique.
2. State the objectives of the experiment.
The objectives of the experiment are
(a) Effect of various geometric parameters on axial spring rate,
(b) Study of percentage influence of each parameter,
(c) To check expected performance of expansion joint,
(d) To verify existing design procedure.
3. Select the quality characteristics and measurement system.
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
200
The initial axial spring rate of the bellow can be measured by spring rate test
as suggested by EJMA. This test is basically non-destructive test. Here the
spring rate is measured by movements of bellows at various pressure values.
The convolution movement can be measured by variations of pitch of the
convolutions. This movement can be measure by vernier caliper. The both
ends must be welded with flanges and their movements should be restricted
by a fixture.
4. Select the factors that may influence the selected quality characteristics.
Here the list of factors to be evaluated in the experiment for their effect on the
selected quality characteristics should be determined. The initial axial spring
rate of bellows depends on following factors
(a) Selection of material and its modulus of elasticity
(b) Selection material thickness,
(c) Design parameter - height of convolutions,
(d) Design parameter - pitch of convolutions
(e) Design parameter Mean diameter of bellow
(f) Design parameter number of plies of material.
5. Identify control and noise factors. (Taguchi-specific)
Control factors are those factors that a manufacturer can control the design of
a product, the design of a process, or during a process.
(a) Control on variations in thickness while forming convolutions.
(b) Control on precise dimension of height of convolutions.
(c) Control on pitch of convolutions.
Noise factors are those things that a manufacturer can not or wishes not to
control for cost reasons.
1. Very high precision level of dimensions
6. Select the levels for the factors.
Basically the spring rate of bellows mainly depends on two parameters for a
particular material. First parameter is thickness and number of plies. As higher
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
201
the thickness, spring rate is increases and for lower thickness the spring rate
will be reduces. These two parameters must be considered as a common
parameter named as total thickness. This will simplify the understanding as a
common parameter.
So, Total thickness = Material thickness x number of plies.
Second important parameter is height of convolutions, as the height of
convolution increases, spring rate reduces and for lower height of convolution
spring rate is always higher.
Here, two levels of parameters can be selected for the total thickness and
height of convolution parameters for the design of experiment.
7. Select the appropriate orthogonal array. [B13, B4]
The determination of appropriate orthogonal array for the experiment is major
criteria for the experiment. Since two parameters are selected for two levels,
following orthogonal array may be selected for the experimentation.
Parameter A = Thickness of bellow material
Parameter B = Height of convolutions
Table 6.1: Experimental parameters for Axial Spring Rate
Thickness of bellow material
t (cm)
Height of convolutions
w (cm)
A1
B1
A1
B2
A2
B1
A2
B2
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
202
Dm E b t p n
w3 C f
(6.1)
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
203
quality characteristic is selected. Due to economic reasons, one test result for
each trial is used in this investigation only the interactions between two factors are
considered and all other interactions are ignored.
No.
1
2
3
Sr.
No.
1
2
3
4
t
(cm)
0.058
0.058
0.065
0.065
w
(cm)
3.5
3.8
3.5
3.8
(6.2)
T2
N
= 92582664 88498208
= 4084456
Ai 2
i 1 nAi
kA
SSA =
T2
(6.3)
= 2705138
4
4
8
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
204
SSA =
A1 A2 2
N
10978 156302
= 2705138
(6.4)
B1 B2 2
N
14940 116682
8
= 1338248
(6.5)
i 1 ( nAxB) i N
(6.6)
2705138 1338248
2
2
2
8
2
= 18
SS (AxB) =
AxB1 AxB2 2
N
= 18
6.7
SSe = 41052
Degree of freedom:
VT = N 1 = 8 1 = 7
VT = VA + VB + V AxB + Ve
VA = kA 1 = 2 1 = 1
VB = kB 1 = 2 1 = 1
VAxB = VA x VB = 1 x 1 = 1
Ve = VT VA VB VAxB
= 71-11
=4
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
205
Sum of squares
(S S)
2705138
1338248
18
41052
4084456
Percent contribution
(%)
65.98
32.51
-0.25
1.76
100
ASR, N/cm
Effect of t
6000
4000
2000
0
0.058
0.065
t, cm
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
206
Effect of w
ASR, N/cm
4000
3000
2000
1000
0
3.5
3.8
w , cm
6.9.4 Observations:
1. The experiment investigation and the subsequent analysis bring out the
influence of dominancy of selected geometric parameters (thickness and
height of convolution) for the axial spring rate of bellows.
2. The thickness is being the most significant parameter (65.98%), followed
by convolution height plays influence of (32.51%) and the combination of
these two parameters affects very negligible (-0.36%) for achievement of
axial spring rate in metallic bellows.
3. The factors are predominant for a confidence level of 95%, since error part
is very negligible, the results may consider reliable.
4. The most significant parameter is thickness of material (t) for desired axial
spring rate.
6.9.5 Limitation:
Spring rate measurement is carried out on four bellows and results are
extrapolated for L-8 orthogonal array. Further if all eight experimental data are
available, influence can be evaluated more precisely.
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
207
The curve shown in figure 6.6 shows the curve of force vs deflection for most
bellows indicates motion extending into the plastic range. The first portion of the
curve is a straight line as the bellows is deflected through its elastic range
(Hookes law). As bellows deflection continues and extends into plastic range, the
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
208
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
209
Db
Dm
(cm)
(cm)
(cm)
(cm)
(cm)
190
193.68
0.06
3.5
E
(N/cm2)
10
19728608
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
210
45.10
45.20
45.30
45.50
Average
change,
cm
45.27
20
44.85
45.00
45.00
45.30
45.04
40
44.60
44.90
44.80
45.00
44.82
60
44.35
44.60
44.50
44.80
44.56
80
44.10
44.25
44.20
44.55
44.28
100
43.80
44.00
44.00
44.25
44.02
45.10
45.20
45.30
45.50
45.27
1.05
1.00
1.00
1.05
1.025
Pressure
N/cm2
Maximum variations
between 20-100
N/cm2.
20
Force
= Pr. x Area
(N)
1570
Unit Deflection
(Reference : 45.27)
(cm)
0.23
40
3140
0.45
6978
60
4710
0.71
6633
80
6280
0.99
6344
100
7850
1.25
6280
Sr.
No.
Pressure
N/cm2
Average: = 6612.2
2
Dbore =100 x (10) 2 = 7850 N
4
4
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
211
Graphs:
9000
8000
Force (N)
7000
6000
5000
4000
3000
2000
1000
0
0
0.2
0.4
0.6
0.8
1.2
1.4
Deflection (cm)
Dm Eb t p n
w3 C f
(4)
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
212
8000
7000
6000
5000
4000
3000
2000
1000
0
0
20
40
60
80
Pressure, N/cm
Experimental
100
120
Analytical
Average Exp
Analytical
Deviation in
Spring rate
Spring rate
spring rate
(N/cm)
(N/cm)
(N/cm)
6610
5454
1156
% deviation
21.19
6.10.8 Observations:
1. Experimental results shows that the spring rate of bellows vary with respect to
internal pressure load. Hence, the average movement of convolution is
considered for various pressure loadings in elastic range. As the pressure
increases towards designed value, the spring rate also approaches to
expected value. In the present study maximum deviation is up to 21.19%.
2. Bellows with lower value of spring rate are flexible, while bellows with higher
spring rate value are stiffer. We desire more flexibility from expansion joints.
3. Stiffness of bellow is directly proportional to mean diameter of bellow,
thickness of material, number of plies of bellow, while inversely proportional to
height of convolutions.
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
213
Db
Dm
(cm)
(cm)
(cm)
(cm)
(cm)
16.90
20.48
0.04
3.5
2.6
E
(N/cm2)
19728608
4.72 f i u q 2
S y Db Ac
= 2.25
Since Lb/Db ratio is less than transition point factor (1.0769<2.25), it is short
column.
Where, fw = Theoretical spring rate = 1998 N/cm/convolution
Sy = Yield strength of material = 20310 N/cm2
Ac = Cross section metal area of one bellow = 0.365 cm2
Critical Pressure (In-plane) = 72 N/cm2
Critical Pressure (Column) Psc =
0.87 Ac S y 0.73 Lb
2
1
= 95.4 N/cm
Db q
C z Db
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
214
2
25.7
26.1
26.1
26.7
26.15
3
26.3
26.1
26.3
26.1
26.2
4
26.7
26.1
26
26.8
26.4
5
26.4
25.8
26.3
26.7
26.3
6
27.1
26.4
26.8
26.7
26.750
0
26.30
28.1
25.8
26.5
26
26.6
26.1
26.1
27.1
26.5
26.45
26.5
26.5
26.3
26.7
26.5
26.7
27
26
27.1
26.7
27.3
26.7
26.5
23.7
26.05
27
26.7
26.5
26.4
26.650
1
26.492
26.1
25.8
27
26
26.225
26.5
26.3
26.8
25.8
26.35
26.5
26.4
26.3
26.5
26.425
26.9
26.9
26.7
26.5
26.75
26.9
26.5
26.7
26.5
26.65
26.9
26.3
26.7
26.5
26.600
2
26.50
26.2
26.3
26.6
25.5
26.15
26.6
26.7
26.6
25.7
26.4
27
25.7
25.7
25.8
26.05
27
26.7
26.3
27.1
26.775
26.6
26.2
26.3
26
26.275
26.6
27
26.2
26
26.450
6
26.35
25.5
26
25.7
25.7
25.725
25.9
26
26.4
26.2
26.125
26.3
26
25.6
27
26.225
26.3
26
26.3
26.5
26.275
26.3
26
26.7
26.7
26.425
26.3
26
26.1
26
26.100
9
26.15
25.9
25.9
26.2
25.5
25.875
25.9
26.3
26.8
25.6
26.15
26.4
26
26.3
27
26.425
26.6
26.4
26.4
26.8
26.55
26.9
26.3
26.3
26.4
26.475
26.3
26.3
26.2
26.3
26.275
12
26.30
26.2
26.7
26.5
26.1
26.375
26.2
26.5
26.5
26.1
26.325
26.3
26.5
26.1
26.9
26.45
26.5
26.5
26.2
26.7
26.475
26.5
26.4
26.1
26.7
26.425
26.5
26.2
26.1
26.5
26.325
15
26.40
1
26.2
26.1
26.2
26.9
26.35
2
26.2
26.1
26.2
26.4
26.225
3
26.3
25.9
26.2
26.4
26.2
4
27.2
26
26.2
26.4
26.45
5
26.6
26.9
26.2
26.4
26.525
6
26.4
26.5
26.2
26.4
26.375
26.35
26.1
26.1
26.2
26.3
26.5
26.1
26.7
26.3
26.9
26.1
26.1
26.7
26.5
26.1
26.2
26.7
26.3
26.1
26.6
26.7
26.2
26.1
26.2
26.4
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
215
26.175
26.4
26.45
26.375
26.425
26.225
26.34
26.8
27.2
27
27.2
27.05
26.8
26.8
27
27.2
26.95
26.8
26.9
26.7
27
26.85
27.1
26.9
26.7
27
26.925
26.9
26.9
26.7
26.8
26.825
26.8
26.9
26.7
26.5
26.725
26.88
27.9
28
28.3
27.5
27.925
26.6
27.2
27.6
27.5
27.225
27.2
26.6
27
26.8
26.9
27.3
26.6
27
27
26.975
26.9
26.8
27.3
27.6
27.15
26.9
26.9
26.9
27.6
27.075
27.20
33
21
33
20.9
26.975
20.4
33.5
20.6
24.7
24.8
27.1
26.9
26.9
26.6
26.875
32.8
21.7
32.7
22.1
27.325
26.8
28.6
27.5
28.2
27.775
24.3
31.8
23.4
31.1
27.650
26.90
AVG. PITCH, mm
Pressure, N/cm
0
10
20
60
90
120
150
180
210
250
290
350
Average pitch, mm
26.30
26.50
26.50
26.35
26.15
26.30
26.40
26.35
26.35
26.90
27.20
26.90
27.4
27.2
27
26.8
26.6
26.4
26.2
26
25.8
25.6
0
10
20
60
90
120
150
180
PRESSURE, N/cm
210
250
290
350
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
216
6.11.5 Observations:
1. Experimental results of squirm test of bellows shows variations of pitch well
within elastic limits up to the pressure 210 N/cm2. But beyond that pressure,
deformation exceeds continuously till squirm failure.
2. The pitch variation suddenly increases from 250 N/cm2, i.e. because of drastic
deformation of bellows beyond elastic limits. Here the pitch disturbs
permanently even after releasing pressure. This is called squirm failure.
3. Bellow should be loaded well within the limits of critical pressure to avoid
squirm failure.
4. In case of short column bellows, it is observed that the bellow initially failed by
in-plane squirm, than subsequently by column squirm.
5. Critical value of pressure suggested by EJMA involves following safety factor.
Factor of safety in in-plane squirm failure = (250 / 72) = 3.47
Factor of safety in column squirm failure = (290 / 95.4) = 3.04
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
217
Pre-compression
(cms)
Total meridional
stresses
N/cm2
N/cm2
N/cm2
0.25
800
69080
69880
0.5
1600
138160
139760
0.667
2140
184300
186440
1.0
3200
276320
279520
2.0
6400
552640
584600
3.0
9600
828960
838560
5.0
16000
1381590
1397590
7.5
24010
2072390
2096400
10.0
32010
2763190
2795200
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
218
Db
Dm
(cm)
(cm)
(cm)
(cm)
(cm)
40.60
42.98
0.08
2.3
2.26
15
E
(N/cm2)
19728608
4.72 f w q 2
= 1.451
S y Db Ac
Since Lb/Db ratio is less than transition point factor, it is short column.
Where, fw = Theoretical spring rate = 33000 N/cm/convolution
Sy = Yield strength of material = 20310 N/cm2
Ac = Cross section metal area of one bellow = 0.458 cm2
Db = Inside diameter of bellow = 42.98 cm,
Limiting critical pressure (in-plane) (Psi) = 53.3 N/cm2
Buckling pressure, (column) Psc =
0.87 Ac S y 0.73 Lb
2
1
= 51.1 N/cm
Db q
C z Db
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
219
12
13
Mode
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
1
18
19
15.5
18.5
66.5
2
17.2
16.6
15.7
16.1
62.7
3
16.4
16.7
15.2
18.2
66.5
4
16.8
15.1
15.5
15.3
62.7
5
15.5
15
15.3
15.6
61.4
6
15.8
15.6
14.6
15.3
61.3
7
15.8
15
16.3
15.4
62.5
8
15.8
14.8
16
16.7
63.3
9
15.6
16.6
15.6
16.7
64.5
10
15.6
15.4
16.5
16.3
63.8
11
16.1
17.5
16.4
17.3
67.3
12
15
14.9
16.1
15
61
13
16.8
17.7
19.9
18
72.4
64.3
17
18
16
17.5
68.5
17
16
15.5
17
65.5
17
18
17
17
69
17
15
15
16.5
63.5
16
16
15.5
15
62.5
16
15
15
16
62
16
15
14
15
60
17
17
16
15
65
16
17
16.5
16.5
66
16
16
15.5
16
63.5
16
17
16.5
18
67.5
16
14.5
15.5
15
61
18
18
20
17
73
65.15
18.5
18
15.5
18.5
70.5
17
16.5
15.5
16
65
17
17.5
17.5
17
69
17
15.5
15
16.5
64
16.5
16
15.5
15
63
16.5
15
15
16
62.5
16
15
14
15
60
16.5
16.5
16.5
15
64.5
16
16.5
16
17
65.5
16
15.5
15
17
63.5
16
17
16
18.5
67.5
15
15
15
15
60
17.5
17
20.5
18
73
65.23
18
18
16
18.5
70.5
16.5
16.5
15.5
16.5
65
17.5
18
17.5
17
70
17
15
15
17
64
16
16
16
15
63
16
15
14.5
16
61.5
16
15
14
15.5
60.5
16
16.5
16
15
63.5
16
17
16
16.5
65.5
16
15.5
15.5
16.5
63.5
16
17
16.5
18.5
68
15.5
15
15
15
60.5
17
18
20.5
18
73.5
65.30
18.5
18
17
18
71.5
17
16
15.5
17
65.5
17
18
17.5
17
69.5
17
15
14.5
17
63.5
16.5
16
15.5
16
64
16.5
15
15.5
16
63
16.5
15
14.5
15.5
61.5
17
16
16
15.5
64.5
16.5
16.5
16
17
66
16.5
16
15
16.5
64
16.5
17.5
16.5
18
68.5
16
15
15.5
15
61.5
17.5
18
20.5
17.5
73.5
65.88
15
22
20
17
74
15
19
18
16
68
16
20
20
17
73
18
13
14
17
62
21
10
12
18
61
21
10
10
18
59
20
10
10
17
57
20
12
10
19
61
19
16
11
20
66
16
16
15
18
65
19
18
21
19
77
14
15
22
11
62
15
20
24
14
73
66.00
Average pitch, mm
0
20
60
90
120
130
64.3
65.2
65.2
65.3
65.9
66
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
220
Movement of convolutions, mm
66.5
66
65.5
65
64.5
64
63.5
63
0
0.2
0.6
0.9
Pressure, N/cm
1.2
1.25
Movement
6.12.6 Observations:
1. In this experiment the pressure intervals are comparatively larger than
previous column squirm test.
2. Experimental results of squirm test of bellows shows average pitch as 16.5
mm instead of 22.6 mm as bellow is compressed by 10 cm.
3. The pitch variations are almost negligible at all pressure values (64.3 to 66.00
for the pressure 0 to 130 N/cm2 ). This is because all convolutions do not have
space or room for the movement as the bellow is compressed.
4. Bellow squirm occurs at 130 N/cm2 pressure.
5. In case of short column bellows, it is observed that the bellow initially failed by
in-plane squirm, than subsequently by column squirm.
6. Critical value of pressure suggested by EJMA includes factor of safety of as
following. Factor of safety in in-plane squirm failure = (130 / 49.2) = 2.64 and
Factor of safety in column squirm failure = (130 / 5.11) = 2.54.
7. The factor of safety is less compared to normal bellow in earlier experiment.
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
221
Db
Dm
(cm)
(cm)
(cm)
(cm)
(cm)
40.60
193.68
0.08
2.3
2.26
15
E
(N/cm2)
19728608
4.72 f w q 2
= 1.451
S y Db Ac
Since Lb/Db ratio is less than transition point factor, it is short column.
Where, fw = Theoretical spring rate = 33000 N/cm/convolution
Sy = Yield strength of material = 20310 N/cm2
Ac = Cross section metal area of one bellow = 0.458 cm2
Db = Inside diameter of bellow = 42.98 cm,
Limiting critical pressure (in-plane) (Psi) = 50 N/cm2
Buckling pressure, (column) Psc =
0.87 Ac S y 0.73 Lb
2
1
= 51.1 N/cm
Db q
C z Db
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
222
A
B
C
D
1
26
24.5
24
24.5
99
2
25
25.5
25
25.5
101
3
25
25
25
24.5
99.5
4
26
24.5
24
25.5
100
5
25
24
24
24
97
6
24
24
24
23.5
95.5
7
25
24
24
25
98
8
25
24.5
25
25
99.5
9
26
25
24
24.5
99.5
10
24
25
25.5
23.5
98
11
25.5
25
25.5
24
100
12
24
25
25
23.5
97.5
13
24.5
25.5
25.5
24
99.5
14
25.5
25.5
25.5
25
101.5
A
B
C
D
25
25
24
25
99
25.5
25
25.5
25.5
102
25
25.5
25.5
24.5
100.5
25.5
24.5
24
25
99
24
23.5
25
24
96.5
24
25.5
24.5
23.5
97.5
24
24
25
25
98
24
23.5
25
25.5
98
25.5
25
23.5
24.5
98.5
23.5
24.5
25
24
97
25
25
25
25
100
23.5
25
25
24.5
98
24.5
25
24.5
23.5
97.5
25.5
26
25
25
101.5
A
B
C
D
25
24.5
24
25.5
99
25.5
24.5
25
25.5
101
25.5
25.5
25
25
101
25
25.5
23.5
25.5
99.5
24
23.5
24.5
24
96
23.5
25
25
23
96.5
24.5
24.5
24.5
25
98.5
24.5
24.5
24.5
25
98.5
25.5
25.5
24
24
99
23.5
25
25.5
23.5
97.5
25
25
25.5
25
101
23.5
24
25
25.5
98
24
25
24.5
24.5
98
25
24.5
25.5
25.5
100.5
10.5
A
B
C
D
25.5
24.5
23
26.5
99.5
25
24.5
24.5
25.5
99.5
25
25
25.5
24
99.5
26
25
23.5
25.5
100
24.5
23.5
24
25
97
24
25.5
24.5
23
97
24.5
24.5
24
24.5
97.5
24
24.5
25
25.5
99
25.5
26
24
23.5
99
23.5
25
25.5
25
99
26
25
25
25
101
23
25
25
25
98
24.5
24.5
25.5
24.5
99
25
24.5
25
26
100.5
13
A
B
C
D
22.5
19
19
32
92.5
26.5
22
23
29.5
101
26
23
26
24.5
99.5
27
24
25.5
25.5
102
23.5
24
26.5
21
95
22.5
30
28.5
18.5
99.5
22
35
26.5
21
105
19.5
35
26.5
22
103
23.5
30
25.5
18
97
23.5
26
26.5
22.5
98.5
27
24
25.5
22
98.5
25.5
22.5
25.5
24
97.5
22.5
22
24.5
26.5
95.5
28.5
16.5
21
35.5
101.5
Average pitch, mm
98.96
98.75
98.79
98.96
98.96
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
223
Movement of convolutions, mm
99
98.95
98.9
98.85
98.8
98.75
98.7
98.65
98.6
0
50
70
105
135
2
Pressure , N/cm
Movement
6.12.12 Observations:
1. In this experiment the pressure intervals are comparatively larger than
previous column squirm test.
2. Experimental results of squirm test of bellows shows average pitch as 25.93
mm instead of 22.6 mm as bellow is extended by 5 cm.
3. The pitch variations are almost negligible at all pressure values (98.75 to 98.96
for the pressure 0 to 105 N/cm2). This is because of bellow is extended by 5
cm. and convolution movement is constrained by tension force.
4. The convolutions became unstable at around 135 N/cm2 pressure. This is
called in-plane squirm. The critical pressure value for instability is 51.1 N/cm2
as per EJMA.
5. Critical value of pressure suggested by EJMA involves following safety factor.
Factor of safety in in-plane squirm failure = (135 / 50.1) = 2.69
Factor of safety in column squirm failure = (135 / 51.1) = 2.64
6. The factor of safety is lowest, while bellow is in compression mode, and
highest when it is in normal mode.
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
224
6.13
Acting
fos
(column)
2.54
2.64
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
225
Above three stages of failure of bellows are snapped and shown below.
Initial condition of
convolutions
Convolutions deformed
laterally - Column squirm
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
226
6.13.1 Observations:
1. Actual squirm failure occurs at minimum 2.5 times the designed critical
pressure.[4] This can be visualized by comparing values of actual critical
pressure and design critical pressure. Hence, this may be considered as
the factor of safety provided in the design procedure.
2. Short bellows having Lb/Db less than transition point factor; the in-plane
critical pressure is always less than column squirm critical pressure. This
observation are agreed and verified with the analytical approach of EJMA.
3. By experimental observation we may conclude that the short bellows
(Lb/Db<Cz), initially deformed by in-plane squirm and subsequently
deformed by column squirm.
4. Bellows may fail by column squirm, if number of convolutions and pitch of
bellows are selected on higher side. As, these two parameters are directly
proportional to the length of bellow. In addition, these bellows will be
amongst the long column bellows.
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
227
6.14
Dynamic Analysis:
Every individual metallic bellows are different in dimensions, and unique for the
applications. The natural frequency of expansion joints must be evaluated
analytically and designer should take care to avoid similar/near by natural
frequency of expansion joint and frequency of vibration, because of pumping
machinery in the piping. Overlapping of both frequencies will leads to resonant
condition and very heavy vibration amplitudes may be created.
A metallic bellow with following dimensions is selected for the analysis.
6.14.1 Geometric dimension of Flanges bellow:
Material: SS 304
Table 6.21: Geometric dimensions of a bellow
Db
Dm
(cm)
(cm)
(cm)
(cm)
(cm)
20
21.62
0.04
1.5
1.3
E
(N/cm2)
19728608
= 9.81
K sr
W
35.3
= 42 Hertz
1.857
The frequency of vibration can be measured with FFT analyzer. In this experiment
FFT analyzer (make: Pruftechnique, Germany) is used to measure natural
frequency. The vibrations are created with rubber coated hammer with manual
hammering on the expansion joint. Total three sets of readings are taken to check
the repeatability of the experiment. The readings are mentioned in table 6.22. The
objectives of an experiment are to measure natural frequency of vibration of
expansion joint. The detailed specifications of FFT analyzer is mentioned in
appendix E.
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
228
33
76
33
77
33
77
Figure 6.18: Axi-symmetry FEA model (Full view and close view)
38
73
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
229
6.14.5 Observations:
1. Analytically natural frequency of expansion joint is 42 cycles/sec, actual
measurement with experiment shows that natural frequency of vibration
is 33 cycles/sec and FEA results shows frequency as 38 cycles/sec.
2. It should be noted that, there are three layers of bellow in the expansion
joint. Hence, the natural frequency vibration is the cumulative natural
frequency of all three layers. Since, the transducer is attached at flange
part. This is an example of parallel mode of frequency.
Ph. D. thesis on Study of Design Aspects of Expansion Joints with Metallic Bellows and their Performance Evaluation
230