BULETIN TIINIFIC, Seria C, Volumul XXIII, Fascicola: Mecanic, Tribologie, Tehnologia Construciilor de Maini

SCIENTIFIC BULLETIN, Serie C, Volume XXIII, Fascicle: Mechanics, Tribology, Machine Manufacturing Technology
ISSN 1224-3264
93
STRESS ANALYSES OF CYLINDRICAL VESSEL WITH CHANGEABLE
HEAD GEOMETRY
Draan Kozak
1
, Ivan Samardi
2
, Antun Stoi
3
,
eljko Ivandi
4
, Darko Damjanovi
5
1,2,3,4,5
Josip Juraj Strossmayer University of Osijek, Mechanical Engineering Faculty in
Slavonski Brod, Trg Ivane Brli-Maurani 2, HR-35000 Slavonski Brod, Croatia
Abstract: The main objective of this paper is numerical analyses of cylindrical pressure vessel with changeable
head geometry (semi-elliptical and hemispherical heads) and comparison of results in means of precision and
time needed for getting the solution. Manufacture technology of pressure vessel cylinders and heads are
described, and construction geometry of various pressure vessel heads is presented. Discretisation style of finite
element models, boundary conditions, and results are detailed shown and explained. Based on analytical
solutions for membrane stress state of pressure vessel, numerical analysis of it is performed also. Comparison of
harvested numerical results for above mentioned pressure vessels are shown tabular, with values of time needed
for getting the solution too. And comparison of analytical and numerical results for pressure vessel with
hemispherical heads is shown too.
Key words: cylindrical pressure vessel, hemispherical head, semi-elliptical head, finite element method, ANSYS.
1. INTRODUCTION
Pressure vessels are inevitably elements of thermal systems, hydro systems, chemic system,
water supply systems etc. It is presumed that pressure vessel is every tank with volume of
> V 1,5 m
3
, inner pressure bigger than 0,05 MPa, or negative pressure smaller than 0,08 MPa,
and accumulated energy > V p 0,02 MPa m
3
.
2. MANUFACTURE TECHNOLOGY OF PRESSURE VESSEL
Parts of cylindrical pressure vessels are manufacturing separately, cylinder and heads.
Cylinder is made from segments which are welded in one unit, and heads are joining with
cylinder by welding too, as shown on Fig. 1.
welds segments head
cylinder
Fig. 1 Welded cylindrical pressure vessel [1]
BULETIN TIINIFIC, Seria C, Volumul XXIII, Fascicola: Mecanic, Tribologie, Tehnologia Construciilor de Maini
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Manufacture of cylinder is beginning with preparing sheet metal in means of cutting on right
dimensions and preparation of edges which must be welded longitudinal. Afterwards, before
final bending, sheet metal must be pre-bended in purpose of correct longitudinal joint (after
final bending) for welding, what is condition for good quality of welded joint. After welding
the cylinder, it must be calibrated to eliminate possible oval shape of cylinder. Then, header
edges for joint of heads must be prepared for welding too. Heads are manufacturing with
procedure of segment pressuring. Manufacture is consisting from following operations:
prepare of material, segment pressuring (Fig. 2), getting final form of head (Fig. 3), preparing
edge for welding (Fig. 4). After that, head is finished and prepared for welding to cylinder.
Fig. 2 Segment pressuring of
pressure vessel head [2]
Fig. 3 Getting final form of
head [2]
Fig. 4 Preparing edge for
welding [2]
Figures from Fig. 5 to Fig. 8 are showing different types of pressure vessel heads.
s
d
i
d
a
s
d
i
R=da
h 3,5s
r
=
0
,
1

d
a
s
d
i
r
=
0
,
1
5
4

d
a
R=0,8da
h 3s
s
d
i
R
=
0
,5
d
i
Fig. 5 Flanged
head [3]
Fig. 6 Shallow
head [3]
Fig. 7 Deep
head [3]
Fig. 8 Hemispherical
head [3]
3. MEMBRANE SHELL THEORY
Shells can be thin-walled and thick-walled. Thin-walled shells are restricted with ratio of plate
thickness and inner or outer radius of shell, as shown in following equations:
,
20
1
s
i
R
s

20
1
s
o
R
s
(1)
Shells with larger value of ratio from equations (1) are thick-walled shells. Fig. 9 shows stress
distribution per plate thickness. That distribution is per hyperbolic state for thick-walled shells
(Fig. 9, a), and per linear state for thin-walled shells (Fig.9, b).
BULETIN TIINIFIC, Seria C, Volumul XXIII, Fascicola: Mecanic, Tribologie, Tehnologia Construciilor de Maini
SCIENTIFIC BULLETIN, Serie C, Volume XXIII, Fascicle: Mechanics, Tribology, Machine Manufacturing Technology
ISSN 1224-3264
95
hyperbole
a) b) straight line
l
l
h
s/ 2
s/ 2
h
N=h s
l
l
M=f s / 6
2
R
R
i
o
Fig. 9 Stress distribution per plate thickness [4]
3.1 PRESSURE VESSEL WITH HEMISPHERICAL HEADS
For calculating Von Mises equivalent stress, hoop and longitudinal stresses are needed, which
have to be calculated from the hoop and longitudinal forces.
a) Pressure vessel cylinder
- Hoop force:
m h
R p N = , (2)
where p is inner pressure and R
m
is average radius of curvature:
2
s
R R + =
i m
(3)
- Longitudinal force:
2
m
l
R p
N

= . (4)
- Hoop stress:
s
N
h
h
= , (5)
- Longitudinal stress:
s
N
l
l
= . (6)
After hoop and longitudinal stresses are calculated, it is possible to calculate Von Mises
equivalent stress [5]:
l h l h eq
+ =
2 2
. (7)
b) Pressure vessel head
In case of pressure vessel head, hoop and longitudinal force are the same:
2
m
l h
R p
N N

= = , (8)
BULETIN TIINIFIC, Seria C, Volumul XXIII, Fascicola: Mecanic, Tribologie, Tehnologia Construciilor de Maini
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Hoop and longitudinal stresses are same too, and because of that, maximal Von Mises stress
of pressure vessel head is equal to hoop and longitudinal stresses [5]:
s
N
s
N
l h
l h
= = = ,
l h eq
= = . (9)
c) Radial displacements
-Pressure vessel cylinder
( )


= A 2
2
2
cylinder
m
cylinder
s E
R p
R
(10)
-Pressure vessel head
( )


= A 1
2
2
head
m
head
s E
R p
R
(11)
d) Condition for membrane stress state
For acquiring a membrane stress state in pressure vessel, plate thickness of cylinder must be
greater than plate thickness of head. Adversely, on pressure vessel joint of cylinder and head,
apart from membrane stresses, bending stress will appear too, so plate thickness of cylinder
must be greater than plate thickness of head, according to following equation [5].
head cylinder
s s

1
2
. (12)
4. GEOMETRY OF CONSIDERED PRESSURE VESSELS
Pressure vessels considered in this paper are completely the same, only difference is in type of
heads. There are two cases: pressure vessel with hemispherical heads (Fig. 10), and pressure
vessel with semi-elliptical heads (Fig. 11). In both cases, internal pressure is p = 1,6 MPa,
inner diameter is d
i
= 5170 mm, cylinder length of pressure vessel is L = 8000 mm and plate
thickness is s = 30 mm.
3
0
4000
O

5
1
7
0
p = 1.6 MPa
R

2
5
8
5
p = 1.6 MPa
3
0
1292,5 4000
O

5
1
7
0
Fig. 10 Pressure vessel with hemispherical
head
Fig. 11 Pressure vessel with semi-elliptical
head
BULETIN TIINIFIC, Seria C, Volumul XXIII, Fascicola: Mecanic, Tribologie, Tehnologia Construciilor de Maini
SCIENTIFIC BULLETIN, Serie C, Volume XXIII, Fascicle: Mechanics, Tribology, Machine Manufacturing Technology
ISSN 1224-3264
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5. ANALYTICAL CALCULATION OF PRESSURE VESSEL WITH
HEMISPHERICAL HEADS
Analytical calculation is performed for pressure vessel with hemispherical heads. Dimensions
and internal pressure are shown on Fig. 10. In this calculation, only Von Mises equivalent
stress for pressure vessel cylinder is calculated, because from membrane shell theory (chapter
3.1) it is obvious that maximal Von Mises equivalent stress will appear on pressure vessel
cylinder, and not on head. Radial displacements of pressure vessel cylinder and head, and
condition for acquiring a membrane stress state in pressure vessel are calculated too, because
of afterward numerical analysis. Results are following:
089 , 120 =
eq
MPa; 4593 , 1 = A
cylinder
R mm; 6008 , 0 = A
head
R mm; 857 , 72 =
cylinder
s mm
6. NUMERICAL ANALYSIS WITH FINITE ELEMENT METHOD
Analysis of pressure vessels in this paper is realised with software ANSYS 11. Three types of
finite elements are used: SOLID 95, PLANE 183 and SHELL 181, which are described in table
1. Material is set as isotropic, linear elastic with Young's modulus of elasticity E = 210000
MPa, and Poisson's ratio = 0,3.
Because of total symmetry of pressure vessel - geometry and load, only 1/8 of pressure vessel
is modeled, and because of that, numerical analysis is much simpler and time for getting
solution is much shorter.
table 1. Description of elements used in analysis [6]
SOLID 95 Description of element
SOLID 95 is defined by 20 nodes having three degrees of
freedom per node: translations in the nodal x, y, and z
directions. The element may have any spatial orientation.
SOLID95 has plasticity, creep, stress stiffening, large
deflection, and large strain capabilities. It can tolerate
irregular shapes without as much loss of accuracy. SOLID 95
elements have compatible displacement shapes and are well
suited to model curved boundaries.
PLANE 183
PLANE 183 is defined by 8 nodes or 6 nodes having two
degrees of freedom at each node: translations in the nodal x
and y directions. The element may be used as a plane element
(plane stress, plane strain and generalized plane strain) or as
an axisymmetric element. This element has plasticity,
hyperelasticity, creep, stress stiffening, large deflection, and
large strain capabilities. It is a higher order 2-D, 8-node or 6-
node element. PLANE 183 has quadratic displacement
behavior and is well suited to modeling irregular.
SHELL 181 SHELL181 is suitable for analyzing thin to moderately-thick
BULETIN TIINIFIC, Seria C, Volumul XXIII, Fascicola: Mecanic, Tribologie, Tehnologia Construciilor de Maini
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ISSN 1224-3264
98
shell structures. It is a 4-node element with six degrees of
freedom at each node: translations in the x, y, and z directions,
and rotations about the x, y, and z-axes. (If the membrane
option is used, the element has translational degrees of
freedom only). SHELL 181 is well-suited for linear, large
rotation, and/or large strain nonlinear applications. Change in
shell thickness is accounted for in nonlinear analyses.
6.1 NUMERICAL ANALYSIS OF PRESSURE VESSEL WITH HEMISPHERICAL
HEADS
Fig. 12 and Fig. 13 are showing finite elements mesh and boundary conditions for pressure
vessel with hemispherical heads. Because of limited length of this paper, only finite elements
mesh for element SOLID 95 is shown (Fig. 12). For all types of finite elements, mesh is
generated automatically, expect on joint of cylinder and head, where mesh is set up with more
density. Fig. 13 is showing boundary conditions. Red arrows are representing inner pressure
of 1,6 MPa, and blue symbols are representing proposed symmetry of pressure vessel.
Because of totally symmetry of pressure vessel, symmetry is set up on all three edges of
pressure vessel part.
Fig. 14 is showing results for Von Mises equivalent stress for pressure vessel with
hemispherical heads meshed with finite element SOLID 95. As expected, the maximal
equivalent stress is appearing on pressure vessel cylinder with amount of 122,997 MPa for
inner pressure of p = 1,6 MPa.
Fig. 12 Finite elements mesh for pressure vessel
with hemispherical heads
Fig. 13 Boundary conditions for pressure vessel
with hemispherical heads
BULETIN TIINIFIC, Seria C, Volumul XXIII, Fascicola: Mecanic, Tribologie, Tehnologia Construciilor de Maini
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ISSN 1224-3264
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Fig. 14 Von Mises equivalent stress for inner pressure p=1,6 MPa - hemispherical heads
Fig. 15 is showing parallel comparison of equivalent stress results for all three type of finite
elements. It is presented only detail of pressure vessel joint of head and cylinder. As figure
shows, stress distribution for all three types of elements is almost identical. In cases of
elements PLANE 183 and SOLID 95 it is possible to see stress distribution per plate thickness
of pressure vessel, but in case of element SHELL 181 it is not possible, and that is
disadvantage in using of this element for numerical analysis. Fig. 15, c) is showing stress
distribution on inner wall of pressure vessel.
Fig. 15 Parallel comparison of equivalent stress results - hemispherical heads;
a) PLANE 183, b) SOLID 95, c) SHELL 181

eq
, MPa
a) b) c)
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6.1.1 NUMERICAL ANALYSIS OF MEMBRANE STRESS STATE
For acquiring a membrane stress state in pressure vessel, plate thickness of cylinder must be
greater than plate thickness of head. Analytical calculation is performed and it is obtained that
plate thickness of cylinder must be 72,857 mm. With numerical analysis it is ascertain that
with increase thickness of cylindrical plate from 30 to 72,857 mm, there is still a bending. It is
obvious from this example that is impossible to acquire membrane stress state, because
membrane stress state neither don't exist, because bending will appear always, in bigger or
smaller amount.
From Fig. 16 it is obvious that equivalent stress values around joint of cylinder and head are
almost the same with amount of ~ 68,5 MPa. Away from joint of cylinder and head, according
to cylinder, stress values are decreasing for about ~ 20 MPa and becomes constant in
continues. Away from joint, according to head vertex, stresses are constant. So, membrane
stress state is prevailed in most of pressure vessel cylinder and head, but not in joint of
cylinder and head.
Fig. 16 Stress distribution (Von Mises) through
plate thickness for pressure vessel with
hemispherical heads, and with inner pressure of
p=1,6 MPa
Fig. 17 Radial displacement for pressure vessel
with hemispherical heads, and with inner pressure
of p=1,6 MPa
Fig. 17 is showing radial displacement regarding to axis of symmetry of pressure vessel. As
figure shows, radial displacements around joint of cylinder and head are almost the same with
value of ~ 0,56 mm. Away from joint of cylinder and head, according to cylinder,
displacement values is decreasing for very small amount, and becomes constant in continues.
Away from joint, according to head vertex, displacement values is approaching value 0. That
is logic, because in axis of symmetry of pressure vessel, there is no radial displacement.
6.2 NUMERICAL ANALYSIS OF PRESSURE VESSEL WITH SEMI-
ELLIPTICAL HEADS
In this case of pressure vessel with semi-elliptical heads will be shown only finite elements
mesh and boundary conditions for element SHELL 181, because for elements PLANE 183 and
SOLID 95 it is same as in case of hemispherical heads, only difference is of course in
geometry of heads. Fig. 18 and Fig. 19 are showing finite elements mesh and boundary
conditions for pressure vessel with semi-elliptical heads. As in case of pressure vessel with
hemispherical heads, in all cases of finite elements, mesh is generated automatically, expect
on joint of cylinder and head, where mesh is set up with more density. In this case of head,
mesh is denser on head vertex too, because of small hole which should be created there.

eq
, MPa
AR, mm
72,857
30
72,857
30
BULETIN TIINIFIC, Seria C, Volumul XXIII, Fascicola: Mecanic, Tribologie, Tehnologia Construciilor de Maini
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Fig. 19 is showing boundary conditions. Red arrows are representing inner pressure of 1,6
MPa, and blue symbols are representing propose symmetry of pressure vessel. As apposed in
earlier case of hemispherical heads, in this case there are orange symbols too, which
represents constraint of rotation. That constraint must be set, because element SHELL 181 has
rotational degree of freedom around certain axis too.
Reason for the small hole placing at the head vertex lies in fact that singularity of stress
appears at this place. Because of singularity, value of stress on head vertex is varying with
number of finite elements, during values of stresses in all rest pressure vessel is the same. So,
to avoid this appearance, small hole on head vertex should be created, and on edge of that
hole, constraint of displacement in radial direction must be set. This constrain is justified to
set, because created hole is assume as endless small, like a point on axis of symmetry of
pressure vessel, and on axis of symmetry, there is no radial displacement. In such of set
boundary conditions, singularity of stresses on head vertex is avoided, and stress distribution
of pressure vessel is correct.
Fig. 18 Finite elements mesh for pressure vessel
with semi-elliptical heads
Fig. 19 Boundary conditions for pressure
vessel with semi-elliptical heads
Fig. 20 is showing the distribution of equivalent stress for pressure vessel with semi-elliptical
heads meshed with finite element SHELL 181. As expected, the maximal equivalent stress is
appearing on minimal meridian curvature of pressure vessel head with amount of 206,081
MPa for inner pressure of p = 1,6 MPa.
Fig. 20 Equivalent stress field for inner pressure p=1,6 MPa - semi-elliptical heads

eq
, MPa
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Fig. 21 is showing parallel comparison of equivalent stress results for all three types of finite
elements. It is presented only detail of minimal meridian curvature of pressure vessel head,
because that is the place of maximal value of stress. As figure shows, stress distribution for all
three types of elements is almost identical. Fig. 21, c) is showing stress distribution on inner
surface wall of pressure vessel.
Fig. 21 Parallel comparison of equivalent stress results-semi-elliptical heads;
a) PLANE 183, b) SOLID 95, c) SHELL 181
7. COMPARISON OF NUMERICAL RESULTS OBTAINED BY USING OF
DIFFERENT TYPES OF ELEMENTS FOR BOTH HEADS GEOMETRY
Tables 2 and 3 are showing comparison of numerical results for both cases of pressure vessel
heads and for all three types of elements. Table 2 is showing comparison of results for
pressure vessel with hemispherical heads, and table 3 is for pressure vessel with semi-
elliptical heads.
table 2. Comparison of numerical results for the pressure vessel with hemispherical heads
Element type
Maximal equivalent stress

eq
, MPa
Mesh parameters, calculating
time
SOLID 95 122,997
Elements: 136 908
Nodes: 217 542
Time: 9 min, 31 s
PLANE 183 122,867
Elements: 3 214
Nodes: 7 361
Time: 2 s
SHELL 181 124,051
Elements: 20 294
Nodes: 10 316
Time: 10,8 s
a) b) c)
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table 3. Comparison of numerical results for the pressure vessel with semi-elliptical heads
Element type
Maximal equivalent stress

eq
, MPa
Mesh parameters, calculating
time
SOLID 95 209,438
Elements: 145 320
Nodes: 229 084
Time: 9 min, 27 s
PLANE 183 209,073
Elements: 5 364
Nodes: 11 727
Time: 2,7 s
SHELL 181 206,081
Elements: 26 186
Nodes: 13 344
Time: 12,9 s
As tables show, results for maximal equivalent stresses for all three types of elements and in
both cases of head type are almost identical. Numerical analysis with finite elements SOLID
95 requires much more elements, because it is need to mesh a volume with plate thickness of
30 mm. And because of bigger number of elements, time for calculating is much longer too.
In case of element SHELL 181 it is needed to mesh a shell, so number of elements and time
for calculating is much smaller. And in case of element PLANE 183 it is need to mesh only a
plane, and in this case number of elements and time for calculating is the smallest of course.
Table 4 is showing comparison of numerical and analytical results for pressure vessel
with hemispherical heads, and percent discrepancy of results. For numerical results is taken
only those calculated with element PLANE 183, and results for analytical calculating is given
in chapter 5.
table 4. Comparison of numerical and analytical results for pressure vessel with
hemispherical heads, percent discrepancy
Type of calculating
Maximal equivalent stress

eq
, MPa
Radial displacements AR, mm
Cylinder
(AR
cylinder
)
Head (AR
head
)
Analytical solution 120,089 1,4593 0,6008
Numerical result 122,867 1,488 0,6084
Percent discrepancy, % 2,26 1,92 1,25
As table shows, all results discrepancy is in allowed boundary of 5%, what means that results
are acceptable!
8. CONCLUSION
In this paper a numerical analysis of pressure vessel with hemispherical and semi-elliptical
heads is performed, with three types of elements: SOLID 95, PLANE 183 and SHELL 181. It
is concluded that in both cases of pressure vessel heads, using of PLANE 183 element
BULETIN TIINIFIC, Seria C, Volumul XXIII, Fascicola: Mecanic, Tribologie, Tehnologia Construciilor de Maini
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presents the best approach, because of minimal number of elements for meshing, shortest
calculation time, insight into the stress distribution per plate thickness and obtained results
which are closest to the analytical ones. This type of axisymmetric element could be
recommended in such cases, when the total symmetry of model is considered (geometry and
load).
Analysis of cylindrical pressure vessel with different head types is performed in purpose of
comparison of values of maximal equivalent stresses. It is concluded that smaller values of
equivalent stresses are appearing in pressure vessel with hemispherical heads, and equivalent
stress distribution is advantageous too in that case of head geometry. Nevertheless, in
exploitation, there is much more pressure vessels with semi-elliptical heads, because
manufacturing of hemispherical heads is much more complicated and expensive.
Maximal equivalent stress for considered vessel geometry in case of hemispherical heads is
appear in pressure vessel cylinder wall with amount of 123 MPa, and in case of semi-elliptical
heads, maximal equivalent stress is almost double (209 MPa) and it is appear on minimal
meridian curvature of pressure vessel head, what is expecting from shell of revolution theory.
Again, nevertheless pressure vessels with semi-elliptical heads are much more manufacturing,
because of earlier mention reason.
It is analytically calculated that for acquiring a membrane stress state in considered pressure
vessel, plate thickness of cylinder must be h
cylinder
= 72,857 mm. Afterwards numerical
analysis is approved that completely membrane stress state in vessel is impossible to acquire,
because bending will appear always, in bigger or smaller amount.
9. REFERENCES
[1] uri, V.: Parni kotlovi, Beograd, Beogradski izdavako-grafiki zavod, 1973
[2] S.I.F.E.A.SpA - Societ Italiana Fondi bombati e Affini; URL: www.sifea.it
[3] Norma: HRN M.E2.252: Proraun podnica izvrgnutih unutarnjem ili vanjskom tlaku
[4] Alfirevi, I.: Nauka o vrstoi II, Zagreb, Golden marketing, 1999
[5] Brni, J., Turkalj, G.: Nauka o vrstoi II, Rijeka, Zigo, 2006
[6] ANSYS, Release 11: Help Topics