Analysis of a Stub End by the Finite Element Method

States of stress present in various weld configurations of stub end

high pressure pipe connections are compared and analyzed
BY N. R. BYERS AND R. F. S C H U L T Z

In the power, petrochemical and

atomic energy industries, the engineer
is called upon to design high pressure
pipe connections with assurance of
high reliability. A bolted flange connection is one of the most common
methods used to attach a pipe to either
another pipe or to a vessel. The portion
of the bolted flange connection here
investigated is called a stub-end and is
shown in Fig. 1.
In the United States, pressure vessels
and connections to these vessels are
usually designed in compliance with
A.S.M.E. Boiler and Pressure Vessel
Codes. However, within the code
limits the stub-end may be fabricated
in several different ways as shown in
Fig. 2.
Since the commercial stub end is
generally a forging it can be considered
a homogeneous material, while those
made by welding can not since in the
heat effected zone the material properties may change. The change may be
caused by a slightly different filler
material, inclusions or voids, or by
thermal effects. The purpose here was to
compare the state of stress present in
each of the stub ends shown in Fig. 2
when subjected to identical loads.
The finite element method was used
to solve the axi-symmetric stress problem of the stub end in which the material
properties of the continuum change in a
localized area due to the thermal effects
of welding. Since the properties of the
continuum are represented by the
properties of the elements comprising
the continuum, this ordinarily complex
problem can be solved by appropriately
varying the physical properties of the
elements in the thermally affected area.
In this manner, an accurate analysis of
stress within the joint can be determined
and the optimum stub end determined.
A 6-in. diameter, 0.028-in. thick wall,
SA-53 Grade B seamless pipe was used

as the basis for comparison. The dimensions of the commercial stub end
are taken from reference 1 and are
given in Fig. 2. The dimensions of the
welded configurations are from reference 2 and are also shown in Fig. 2.
The condition of loading was computed
using the methods of A.S.M.E. Section
VIII and calculations were made using
the maximum load permitted for materials between 20F and 650F; however, the pipe is assumed to be adequately supported so that no load is

caused at the flanged joint due to weight

or thermal expansion.
It was assumed that the commercial
stub end and the components for the
welded configurations were fabricated
of SA-53 Grade B, with material
properties as follows:
Young's modulus, E = 30 x IO6 lb/in2
Poisson's ratio, v = 0.250
Yield point stress = 35,000 lb/in2

STUB-END AND LAP JOINT FLANGE CONNECTION

1465 PSI

8275 PSI

*-

7660

PSI

"

1465 PSI

CONDITION OF LOAD

N. R. BYERS is Professor of Mechanical

Engineering, New Mexico State University. R. F. SCHULTZ is a Captain in the
United States Air Force.

Fig. 1Sketch gives details of stub end and lap joint flange connection as well as
condition of load

WELDING

RESEARCH

S U P P L E M E N T I 31-s

0.280 .

1/2 R

JL
WELD CONFIGURATION NUMBER 2

4.2500R

0.280

Ti

3.0325R

_JLJt
DIMENSIONS OF COMMERCIAL STUB-END
-0.280

4.2500R

0.280 ,

WELD CONFIGURATION NUMBER 3

STUB-END CONFIGURATIONS TESTED

Young's modulus = 28.5 x IO6 lb/in2

Poisson's ratio = 0.265
Yield point stress = 60,000 lb/in2
The configurations of Fig. 2 were
divided into axi-symmetric triangular
finite elements of coarse, intermediate
and fine mesh (Fig. 3) to demonstrate
convergence of stress values.
The nodes which were under the
flange were fixed in the z direction and
the remaining nodes were free to displace as the external loads dictated. The
external loads were applied at the
boundary nodes as shown in Fig. 1.
The material properties of the individual
elements were varied as required to
represent weld material or parent metal.
The r and z coordinates of the nodes in
the undeformed configuration were
determined and the information entered
as data in a computer program developed by E. L. Wilson3 and modified
by R. E. Narum 4 of the Idaho Nuclear
Corporation.
The stresses and strains at each
element node were found according to
the equations:
32-s-| J A N U A R Y

1972

3.0325R

DIMENSIONS OF WELD CONFIGURATIONS a WELD

CONFIGURATION NUMBER I

Fig. 2Geometry and dimensions of stub ends tested

The material properties of weld
metal as deposited were obtained from
the United States Steel Corporation
Research Center, Monroeville, Pennsylvania. Filler metal of type E60 and E70
class for welding had the following
properties:

M =[7V(5)]{5}

(1)*

U} = [r ()]{}

(2)

and the corresponding three nodal

stresses averaged for the final comparative centroidal stress values. The
stresses and coordinates of the centroid
for each element comprised the output
of computer program. The resulting
stresses were plotted as contours on the
stub end with convergence of stress
values observed as the element size
was decreased. No significant stress
differences (Aa g 5%) were observed
among the stub ends analyzed. A
typical contour stress plot is shown in
Fig. 4.
References
1. Steel Butt-Welding Fittings, HSA B
16.9-1958, The American Society of Mechanical Engineers, New York, N.Y., 1958,
Table 9.
2. A.S.M.E. Boiler and Pressure Vessel
Code, Section VIII, "Rules for Construction of Unflred Pressure Vessels," The
American Society of Mechanical Engineers,
New York, N.Y., 1965.
3. E. L. Wilson, "A Digital Computer
Program for the Finite Element Analysis
of Solids with Nonlinear Material Properties," Technical Memorandum No. 23,
Aerojet-General Corporation, Sacramento,
California, July 1965.
4. R. E. Narum, "A Guide for Input
Preparation for the GAS Computer Program," Idaho Nuclear Corporation, Idaho
Falls, Idaho, Revised November, 1969.
5. M. F. Rubinstein, "Matrix Computer
**See appendix (A) for the derivation of
these equations.

Analysis of Structures," Prentice-Hall, Inc.,

Englewood Cliffs, N.J.. 1966, Chs. 3, 6, and
12.
6. S. Timoshenko, J. N. Goodier,
"Theory of Elasticity," 2nd ed., McGrawHill Book Company, Inc., New York, N.Y.,
1951.
7. O. C. Zienkiewicz, "The Finite Element Method in Structural and Continuum
Mechanics," McGraw-Hill Publishing Company Limited, McGraw-Hill House, Maidenhead. Berkshire, England. 1967, Chs. 1-4.
8. M. J. Turner, R. W. Clough, H. C.
Martin, and L. J. Topp, "Stiffness and
Deflection Analysis of Complex Structures," Journal of the Aeronautical Sciences, Vol. 23, No. 9, September 1956, pp.
805-23.
9. J. H. Argyris. "Matrix Analysis of
Three-Dimensional Elastic Media Small and
Large Displacements," Journal of the
American Institute
of Aeronautics and
Astronautics, Vol. 3, No. 1, January 1965.
10. R. W. Clough, "The Finite Element
Method in Plane Stress Analysis," Proceedings of the 2nd Conference on Electronic Computations, American Society of
Civil Engineers, September 1960, pp. 345-78.

APPENDIX A
Derivation of the stress and strain
relationships in equations (1) and (2)

M =tr,(S)]{s}

(i)

IT, ()]{}

(2)

The transformation matrices, [T, (5)]

and [T( (5)] are derived known quantities6 and once the displacement {5} is
known \a) and {e} can be found.
Since the displacement {} and the resultant nodal forces \F] are related by
the stiffness matrix [K] as
[*]{*}

(3)

the problem becomes one of finding the

6 x 6 stiffness matrix [K] in order to
evaluate {&}. To generate [K] for an
element, a unit displacement is applied
to one of the coordinates and the forces
required to hold each of the remaining
coordinates fixed are computed. The
displacement of each coordinate generates one column in [K] and as each
coordinate is in turn displaced the complete stiffness matrix is generated.
Applying the concept of virtual work
the individual matrix. elements ku of
[K] can be determined by

ku = J

f<r} . '{}< dv

SK
ESS

(4)

Where
lb/in2

And
INTERMEDIATE

in/in

The subscript /' in {cr} y denotes that the

stress vector corresponds to the unit
displacement at coordinate j only, and
in a like manner {e},: corresponds to a
unit displacement at the coordinate i
only.
Rubinstein5 derived equation (4) using concept of virtual work. The fundamental relation is
(External virtual work)
= (Internal virtual work)

.j

MESH

(5)

Equation (5) can be written as

*\ \

\
^

COARSE

MESH

^J

Fig. 3The configurations of Fig. 2 have been divided into coarse, intermediate
and fine meshes

/External
\ /
I Virtual
) ( Real
\Displacement/ \Forcey
/Internal
\ /lnternal\
= ( Virtual
1 I Real
1 (6)
\Displacement/ \Force /
Under an applied load the internal
displacements of the media may be of
the forms: axial, bending, shear and
torsional.
Element ky of a stiffness matrix [K]
is defined as the force required at coordinate i to produce a unit displacement at coordinate j only (zero displacements at all other coordinates).
By the concept of virtual work, element
ku of the stiffness matrix [K] is equal in
magnitude to the work done by the
forces at the coordinates in the displaced configuration when column i of
[K] is generated. This is due to ut and
Uj being the only virtual displacements
which are present in the displaced configuration described with all other displacements equal to zero. All forces
which do not act over some displacement do no work and as a consequence

R - STRESS
FIGURE

Fig. 4Typical contour stress plot

WELDING

RESEARCH

S U P P L E M E N T | 33-s

are eliminated.
Now if the virtual displacement of
equation (6) is set equal to unity,
/Real \
(1) \ Forces/
/Internal
\ /InternalX
= ( Virtual
J ( Real
J (7)
\Displacements/ \Force /
and
(kii)(ui = 1)
= (internal stresses trgj for Uj = 1)
times (internal strains e.S; for ut = 1)

Fig. 5Triangular element in axi-symetric stress

or

and with the strains for axi-symmetric

stresses known 6

T,hsi esi dv

k ij

(8)

dbz

U f

lrJ

The stress-strain relationship is used

to find [Ta (5)] in terms of 5
,

Tz '

+ 6V

'

5L + a2 + a3 ?!
r
r
a3 + as

strain
strain
strain
, shear

in the r direction
in the z direction
in the 8 direction
strain

Equation (9) represents only the

element k^ of the stiffness matrix [K];
to obtain the complete stiffness matrix,
equation (9) must be summed over all
ij, and may be written as
(4)

5, (r,z) = ai + a2r + a3z

52 (r,z) = a4 + a$r + a6z

(1

34-s I J A N U A R Y

1972

-v)

(1 - ") 1

0
0
1
r
0

[Bl =

1 0 0 0
0 00 1
1z 0 0
r
0 1 0 0

1 - 2v
2 (1 - v)_

(12)
0
0
0

E = Young's modulus, lb/in

(19)
2

v = Poisson's ratio
1

Now substituting equation (16) into

equation (18)

Where

[N][B][CTl i&\
a3
Ui

(13)

(20)

And comparing equation (20) with

equation (1) then is seen that
[T(m

a5

=[N][B][C]~

(21)

APPENDIX B
Equation (10) may be written as
()

=[C]{a]

C A L C U L A T I O N S F O R FORCES O N S T U B E N D

(14)

Where

[C]

1
1
1
0
0
0

P E R A . S . M . E . BOILER A N D PRESSURE VESSEL

C O D E , S E C T I O N VIII 2

Calculation for Allowable Pressure

(Design Pressure)

nziOOO
r.zjOOO
r,z,0 0 0
0 0 1 n Zi
0 0 1 7-2 z2
0 0 1r,z,

From paragraph UG-27 (longitudinal stress)

2SEt
R - 0.4/
where

By equation (14)
(10)

(12)

To find the vectors \tr\j and {},* in

order to apply equation (4) the two
transformation matrices [T (b)] and
[Tt (5)] must be evaluated since \a)j
and {t j , are unknowns.
By assuming linear strain relations as

in the r direction
in the z direction
in the 6 direction
stress

1 - vl - V

stress
stress
stress
i shear

E(l
-v)
(1 + v) (1 - 2v) times

[N]

where

Trz

Where

{<r\TU}*dv

!
J

'

then

[B] [a]
k~

{r z)

(11)

a2

(18)

[N]{e]

dbz ,

(9)

where the total work is obtained by

adding the work done by the six stress
components in the xyz coordinate
system instead of summing over the
four energy forms. For the axi-symmetric case, which has three normal
stresses, a shearing stress and corresponding strains, equation (6) reduces
to

(17)

IT, (5)] = [B] [C]"

(r,z)

{r z)

til 2-1 J V tri dv

(16)

Now by comparison of equations (16)

with (2) is seen that

(r,z)

dbr,

(12) and

[5][crMl

{dbr
dr~(r'Z)

where the subscripts S refer to the four

possible forms of strain energy: axial,
bending, shear and torsional. The subscript j in (TSj indicates that the stresses
correspond to a unit displacement at
j and the strains eSi correspond to a unit
displacement at i.
Equation (5) can also be written as

Now combining equation

equation (15) is found

{} =tcrM*i

(15)

/ = minimum required thickness of

shell = 0.280 in.

E = joint efficiency = 0.70 for uninspected weld

R = inside radius = 3.0325 in.
P = design pressure,
square inch (psi)

pounds

per

S = maximum allowable stress value

= 15,000 psi
2 (15,000) (.70) (.280)
3.0325 - .4 (.280)

tact between flange and

inches = 7.9050
H = total hydrostatic end
pounds = 0.785 G2P

Tensile Stress in Pipe

(Longitudinal)

lap,
force,

S =

Ri = inside radius, inches = 3.0325

R2 = outside radius, inches = 3.3125
P = design pressure, pounds
square inch = 1465

Wmi = minimum required bolt load

for the operating conditions,
pounds

Circumferential Stress

where E in this case is 1.0 because the

tubing is seamless.

WmX = 71,750 +35,600

P = 1465 psi
The design pressure must be the lesser
value of the longitudinal or circumferential design pressure or 1465 psi.

= 71,750 pounds

HP

= 35,600 pounds

5 =

The required bolt load for operating

conditions is

Wm2 = minimum required bolt load

for gasket seating, pounds

Wml = H + HP = 0.785 G'P

+ (26) (3.14 GmP)

v = gasket or joint-contact-surface
unit setating load, pounds per
square inch = 400 for rubber
gasket with cotton fabric insertion

b = effective gasket or joint-contact-surface

seating
width,
inches = 0.392, for gasket made
of rubber with cotton fabric
insertion
G = diameter at midpoint of con-

Wml

3.14 [/?!2 -

Rfl

where
3.UbGy

Wmi = bolt load, pounds = 107,350

where

where

= 7660 psi

The compressive stress due to the

bolting load is

The minimum initial bolt load required

to seat the gasket is
W,

Calculation for Bolt Load

(Appendix II)

= tensile stress, pounds per square

inch

Compressive Stress Due to

Bolting Load

Wml = 107,350 pounds

_ (15,000) (1.0) (.280)

(3.0325) - .6 (.280)

per

(3.0325)2 (1465)
~ (3.3125)2 - (3.0325)2

Wml = 0.785 [7.905]2 [1465] +

2 [.392] [3.14] [7.9050]
[1.25] [1465]

SEt
P =
J? + .6/

Ri2

where

m = gasket factor (dimensionless) =

1.25 from table UA-49-1 for
rubber with cotton fabric insertion
P = design pressure = 1465 psi

P = 2010 psi

RSP
RT2 -

Ri

= outside radius of lap, inches

= 4.2500

R2

= radius at midpoint of contact

between flange and lap, inches = 3.9525

= compressive stress, pounds per

square inch
35,600
3.14 [4.25002 - 3.95252]

Wm2 = 3.14 [.392] [7.9050] [400]

Wml = 3890 pounds

Since Wa > Wm2, Wm\ is the required

bolt load.

=4.625 psi

The loads computed in this appendix

are depicted in Fig. 1.

NEW BOOK from WELDING RESEARCH COUNCIL

Weldability

of Steels

by
Robert D. Stout, D e a n of Graduate School,
L e h i g h University
and
W. D'Orville Doty, Research Consultant,
U. S. Steel Corporation
The Second Edition of the book Weldability of Steels by R. D. Stout and W. D.
Doty has been published in order to update information contained in the First Edition
which was published in 1953. A substantial amount of the research carried out since
publication of the First Edition has been supported by the American Iron and Steel Institute, and due acknowledgment is hereby made for this sponsorship. This Second Edition
represents the diversified thinking and experience of many individuals.
One of the most useful parts of this 430-page book is a table describing suggested
procedures for welding steels meeting standard specifications. This table should be available to all engineers concerned with welding.
The price of this book is $12.00 and includes postage. All orders must be accompanied by checks payable to the Welding Research Council, 345 East 47th Street, New
York, N. Y. 10017.

WELDING

RESEARCH

S U P P L E M E N T I 35-s