On the use of the stratified momentum balance for the deduction of shear stress in horizontal gas–liquid pipe flow

The use of the stratified flow momentum balance for the deduction of interfacial and liquid wall shear stresses from experimental measurements is examined. A systematic error analysis is applied to the governing equations using the principle of maximum uncertainty. A series of air–water experiments were conducted in 50 and 80 mm diameter pipes, in which gas pressure drop, liquid height and gas wall shear stress were measured. A framework for the correlation of the deduced shear stresses is proposed from the experimental measurements. The uncertainty analysis is used to show that the definition of mean liquid height does not significantly influence the overall results. The development of empirical equations based on such methods may lead to total uncertainties of up to 40%, irrespective of accuracy of the experimental data or the appropriateness of the correlating technique. Comparisons with state-of-the-art correlations for the liquid wall and interfacial friction factor data showed even larger discrepancies between measurement and prediction.     

On the use of the stratified momentum balance for the deduction of shear stress in horizontal gas–liquid pipe flow

The use of the stratified flow momentum balance for the deduction of interfacial and liquid wall shear stresses from experimental measurements is examined. A systematic error analysis is applied to the governing equations using the principle of maximum uncertainty. A series of air–water experiments were conducted in 50 and 80 mm diameter pipes, in which gas pressure drop, liquid height and gas wall shear stress were measured. A framework for the correlation of the deduced shear stresses is proposed from the experimental measurements. The uncertainty analysis is used to show that the definition of mean liquid height does not significantly influence the overall results. The development of empirical equations based on such methods may lead to total uncertainties of up to 40%, irrespective of accuracy of the experimental data or the appropriateness of the correlating technique. Comparisons with state-of-the-art correlations for the liquid wall and interfacial friction factor data showed even larger discrepancies between measurement and prediction.     

An Integrated Approach to the Separation of Principal Surface Stresses Using Combined Thermo-Photo-Elasticity

A new instrument capable of the full-field separation of principal stresses on the surface of a component is presented. The instrument combines the techniques of thermoelastic stress analysis and reflection photoelasticity in a single optical head, permitting the simultaneous capture of both data from the same point of view. A single strain witness coating is employed for the acquisition of both the thermoelastic and photoelastic data, which is both birefringent under applied stress conditions and opaque at the infrared wavelengths to which the thermoelastic analysis system is sensitive. This enables the combined technique to be performed continuously from the same surface during loading. The performance of the new instrument is validated in the analysis of a classical laboratory specimen of known geometry. Separated stress data from the experiment is compared to simulated data, demonstrating that the accuracy of the stress separation technique is comparable to that of the individual thermoelastic and photoelastic techniques, and it is concluded that combined thermo-photo-elasticity is a powerful tool for the experimental separation of principal surface stresses.     

Experimental Evaluation of Residual Stresses in Pipes Manufactured by UOE and ERW Processes

Pipes are basic elements used in the construction of pipelines for the long-distance transportation of oil and gas and their derivatives. They can be manufactured by cold forming processes such as UOE and ERW, both widely used in the oil and gas industry. These processes produce high levels of non-uniform plastic deformation, which introduce a new state of residual stress into the material. In some cases, these stresses combine with mechanical stresses generated by external loads leading to service failures, interrupting the transmission line and increasing the risk of accidents. Therefore, determining in advance the residual stress distribution in pipes is an important task which involves the evaluation of the structural integrity. Six pipe samples obtained by the UOE and ERW processes were measured and evaluated using a portable optical device that combines radial in-plane digital speckle pattern interferometer (DSPI) with the incremental hole-drilling technique to measure residual stresses. The experimental results indicate a distinct residual stress distribution for each manufacturing process, while the measured residual stress distributions in the longitudinal and circumferential directions were similar at all measurement locations along an individual pipe.     

Measurement of the Distribution of Residual Stresses in Layered Thick-Walled GFRP Pipes

The objective of this study is to measure the axial, circumferential, shear and radial residual stress distributions in three thick-walled glass fibre reinforced plastic (GFRP) filament-wound pipes, two of which are layered. The measurement of residual stresses was carried out using a recently published layer removal method which overcomes the limitations of previous techniques and can be applied to layered anisotropic pipes of any wall thickness. Layers of approximately 0.3 mm thickness were incrementally ground from the outer surface of the pipes. The resulting strains were measured on the inner surfaces. A least-squares polynomial was fitted to each measured data set, and used to calculate the corresponding stress distributions. All of the resulting axial, hoop and shear stress distributions adhere to the requirement of self-equilibrium and the radial stress distributions all vanish to zero at the inner and outer surfaces. The radial stresses of the layered pipes showed a tendency to have two peaks, one for each layer, a consequence of the two-stage manufacturing process of these pipes. The measured axial and hoop stresses of all three pipes were similar at the inner surfaces despite significant differences in the stiffnesses in the principal directions arising from different wind angles.     

Assumed stress quasi-conforming triangular element for couple stress theory

In this paper, a 3-node triangular element for couple stress theory is proposed based on the assumed stress quasi-conforming method. The formulation starts from polynomial approximation of stresses. Then the stress-function matrix is treated as the weighted function to weaken the strain-displacement equations. Finally, the string-net functions are introduced to calculate strain integration and the stress smooth technique is adopted to improve the stress accuracy. Numerical results show that the proposed new model can pass the C~(0-1) patch test with excellent precision, does not exhibit extra zero energy modes and can capture the scale effects of microstructure.     

Experimental methods of X-ray stress analysis

A technique is described for measuring residual stresses in steels and composite materials by X-ray diffraction. Specimen preparation, X-ray diffractometer alignment, diffraction-peak location, and the determination of the elastic modulus, Poisson's ratio and stress factor are covered. Application examples include measurement of heat-treating and shot-peening stresses in steels and grinding and temperature stresses in WC-Co composites.     

Separation of dynamically induced low-frequency stresses in rods and pipes

Expressions are evaluated with which the separation of oppositely propagating axial-stress components in rods and pipes can be achieved from stress waveforms obtained at different locations on the rod or pipe. The corresponding measurement/processing procedures can produce either the power spectra or the waveforms of these components. Simplifications of basic procedures for waveform evaluation are formulated whenever possible.A few experiments are described which verify the analytical results obtained theoretically and which also demonstrate the applicability of the separation procedures.     

Validation of Mechanical Strain Relaxation Methods for Stress Measurement

Most validation studies of mechanical strain relaxation (MSR) methods for residual stress measurement rely on using the saw-tooth residual stress distribution resulting from four point bending and elastic–plastic deformation. Validation studies using simple applied stress profiles in rectangular steel beams are used in this work, together with beams subjected to elastic–plastic bending. Two MSR methods are explored, deep-hole drilling (DHD) and incremental centre hole drilling (ICHD). As well as a series of experiments, finite element analyses are conducted to determine the accuracy in the inversion of measured deformation to reconstruct stress. The validation tests demonstrated that apart from the applied stresses, the initial residual stresses also contribute even when samples are expected to be stress free. The uncertainty in measurement for the two MSR methods is determined, with the uncertainty in near surface measurement found to be significantly larger than uncertainty for interior measurement. In simple loading cases (and simple stress profiles) the uncertainty in measurement and hence the degree of validation is shown to be within about ±50 MPa for steel for “known” stress up to about 140 MPa. However, if the residual stress distribution is more complex there arises increased uncertainty in the predicted residual stress and lack of confidence between measurements methods.     

Time to Creep Failure of Thin-Walled Cylindrical Pipes under Torsion

The time to creep failure is calculated for rectilinear thin-wall pipes subjected to pure torsion, torsion with uniaxial tension, and torsion with internal pressure. The problem is solved using the concept of equivalent stress. The equivalent stresses are found from the generalized mixed failure criterion whose form depends on the signs of the principal stresses. The criterion relates the maximum normal stress and the intensity of shear stress if the signs coincide, and the maximal shear stress and the octahedral shear stress if the signs are opposite. A technique for determining the material constants is developed. The calculated and experimental data are compared and found to be in satisfactory agreement     

Application of X-ray diffraction, micromagnetic and hole drilling methods for residual stress determination in a ball bearing steel ring

A basic understanding of distortion problems requires the analysis of a complete manufacturing process including an almost complete overview of residual stress states in the component during each production step. To reduce the measurement time in the future, three measurements methods (X-ray diffraction, micromagnetic and blind hole drilling methods) have been used to analyze residual stress states in machined AISI 52100 ball bearing rings. X-ray diffraction was used as a state-of-the-art method for machining induced residual stresses with pronounced gradients. The ring exhibited a complex residual stress state with high tensile residual stresses at the surface, a strong gradient in depth, and also showed some variation along the outer circumference due to a superimposition of machining induced residual stresses and effects from the clamping device process. Due to this surface state, micromagnetic signals depend on the analyzing frequency. A calibration of the signals was only possible with the X-ray diffraction data. The results of the three different measurement methods correlate reasonably well.     

Local stress measurement using the thermoelastic effect

A technique for measuring local stresses in metallic specimens is proposed and tested. The technique depends on the experimental measurement of temperature changes in stressed members due to adiabatic elastic deformation. At a free boundary in a body under plane stress, these temperature changes are directly related to the value of the tangential principal stress. The technique is suited for measurement of stress-concentration effects, since the temperature changes can be measured with thermocouples featuring extremely small junctions. A simple stress-concentration geometry, the finitewidth strip with a central circular hole, is chosen as a model system for this study. Heat transfer in this geometry due to the temperature gradients produced by elastic deformation is analyzed. It is shown that the ratio of the temperature change at a reference section to the change at the locale of the stress concentration can be used to determine the stress-concentration factor, allowing for heat-transfer effects. An experimental measurement system capable of obtaining reproducible results with the thermal-measurement technique is described, and experimental results are given for the model geometry which agree favorably with theoretical predictions. Application of the technique to other problems is discussed.     

Plasticity Effects in the Hole-Drilling Residual Stress Measurement in Peened Surfaces

The incremental hole-drilling technique (IHD) is a widely established and accepted technique to determine residual stresses in peened surfaces. However, high residual stresses can lead to local yielding, due to the stress concentration around the drilled hole, affecting the standard residual stress evaluation, which is based on linear elastic equations. This so-called plasticity effect can be quantified by means of a plasticity factor, which measures the residual stress magnitude with respect to the approximate onset of plasticity. The observed resultant overestimation of IHD residual stresses depends on various factors, such as the residual stress state, the stress gradients and the material’s strain hardening. In peened surfaces, equibiaxial stresses are often found. For this case, the combined effect of the local yielding and stress gradients is numerically and experimentally analyzed in detail in this work. In addition, a new plasticity factor is proposed for the evaluation of the onset of yielding around drilled holes in peened surface layers. This new factor is able to explain the agreement and disagreement found between the IHD residual stresses and those determined by X-ray diffraction in shot-peened steel surfaces.     

双向应力状态下三维球形空穴应力集中的实验研究

用光弹三维应力冻结切片法研究了双向应力状态下球穴附近应力分布和集中问题，介绍了含球穴的三维光弹性模型的尺寸确定、浇注工艺和实现双向应力状态及大面积均匀拉伸加载的方法，分析了在特定平面上的正应力σ，剪应力τ沿球穴边缘的分布及衰减规律。文中对实验数据进行了统计分析处理，证明了实验与理论结果符合一致     

A laser Doppler anemometry technique for Reynolds stresses measurement

A technique is described for the measurement of all components of mean velocity and Reynolds stresses, in a complex turbulent flow where achieving coincidence data acquisition is difficult. The method is based on data recorded using four orientations of the laser probe. It is shown that the measurement errors are not the same for all the components of the Reynolds tensor, but they are sufficiently small to give a good accuracy. An application to a turbomachinery flow is given to illustrate the method.     

A recording photoelastic stress meter

An instrument for automatically making photoelastic measurements of stress is described. It may be used for recording transient stresses at a point or for scanning spatial stress distributions. Its use is illustrated by an application entailing the measurement of transient thermal stresses in a viscoelastic material.     

依据控制致裂钻孔应力变化确定原岩应力的平行钻孔法的研究

为了寻求一种操作简单、低成本的岩体应力测试方法, 本文提出了一个依据控制致裂钻孔应力变化的量测推算原岩应力的改进平行钻孔法。本文阐明了平行钻孔法岩体应力量测的特点和控制致裂法的原理。介绍了依据控制致裂钻孔应力变化确定岩体应力的基本理论。     

Calculating the Time to Creep Failure of Thin-Walled Pipes under Internal Pressure

The time to failure is calculated for thin-walled pipes subjected to internal pressure, to internal pressure and tension, and to internal pressure and bending. The problems are solved using the concept of equivalent stresses. The equivalent stresses are found from a mixed delayed-failure criterion relating the maximum normal stress and the intensity of tangent stresses. The criterion includes an additional material constant, which is determined experimentally. The calculated results and experimental data are compared and found to be in satisfactory agreement     

Constitutive Model Calibration for Powder Compaction Using Instrumented Die Testing

Calibration procedures for constitutive models for powder compaction are presented. A practical calibration method based on a die compaction experiment is presented. A newly developed apparatus consisting of a die instrumented with radial stress sensors is described. The paper proposes two contributions to account for errors present in instrumented die testing, which are due to 1) elastic compliance of the testing frame, influencing the measurement of axial strain and 2) the presence on non-homogeneous stress state in the test specimen. It is shown that system compliance is important for generating an accurate stress-strain curve for compression. The effect of different compliance correction methods is evaluated with regard to the accuracy of models predicting pressing forces. The system compliance becomes more significant during unloading in the die; this information is used to determine the elastic properties. A new compliance correction method is introduced following a detailed analysis of the forces and deformations of different parts of the loading frame. In instrumented die compaction the axial and radial stresses are measured at fixed locations and the specimen is subject to non-homogeneous stresses and strains due to the effect of friction between the powder and die wall. Starting from the Janssen-Walker method of differential slices a method to account for non-homogeneous stress and strain is developed.     

Measuring Inaccessible Residual Stresses Using Multiple Methods and Superposition

The traditional contour method maps a single component of residual stress by cutting a body carefully in two and measuring the contour of the cut surface. The cut also exposes previously inaccessible regions of the body to residual stress measurement using a variety of other techniques, but the stresses have been changed by the relaxation after cutting. In this paper, it is shown that superposition of stresses measured post-cutting with results from the contour method analysis can determine the original (pre-cut) residual stresses. The general superposition theory using Bueckner’s principle is developed and limitations are discussed. The procedure is experimentally demonstrated by determining the triaxial residual stress state on a cross section plane. The 2024-T351 aluminum alloy test specimen was a disk plastically indented to produce multiaxial residual stresses. After cutting the disk in half, the stresses on the cut surface of one half were determined with X-ray diffraction and with hole drilling on the other half. To determine the original residual stresses, the measured surface stresses were superimposed with the change stress calculated by the contour method. Within uncertainty, the results agreed with neutron diffraction measurements taken on an uncut disk.