LAUSR

Abstract The fatigue life prediction and associated fail-safe design of autofrettaged tubes require accurate stress modeling of each specific high-strength thick-walled cylinder during and after the autofrettage process, which depends largely on the elastoplastic behavior of the original steel tubes. However, the complex material behavior is dominated by the Bauschinger effect. Modeling swage autofrettage of such steel tubes remains problematic. This is a crucial issue that has not been resolved by any available modeling software. Therefore, the modeling and design of the autofrettage process for current and future materials depends upon extending the capability of current software. This research aims to develop a user-programmable function (UPF), USERMAT, to realize a user-defined material model that features true material constitutive behavior with the corresponding algorithms for accurate stress analysis of high strength thick-walled cylinders during the autofrettage process. The material constitutive model to be implemented can be formulated with high accuracy via an available material characterization, which can adapt to both nonlinear and linear strain hardening during the initial tensile loading, while the elastic modulus can be reduced during reversed-loading. It also incorporates the Bauschinger effect as a function of the prior tensile plastic strain during the nonlinear compressive reversed-loading phase and fits the experimental data of the true material model. Swage autofrettaged thick-walled cylinder case studies were reported. The results for residual radial and hoop stress and for elastic strain components were compared with independent, available neutron diffraction measurements, and they are in good agreement. Developing and integrating such a UPF into a standard finite element analysis software package is potentially the most significant unsolved fundamental modeling issue relating to re-yielding, fracture and fatigue of modern autofrettaged cylinders and pressure vessels. It can not only provide a fundamental understanding of the deformation mechanism and stress development within the high strength steel tubes during the autofrettage process, but also provide guidance for the design and optimization of the autofrettage manufacturing processes and of material selection for high intensity pressure vessels, a potential market of billions of dollars.