Optimization Design of the U-shaped Metal Bellows
Ling Yang1, Mingjin Yang1*, Feng Liu1, and Guocai Yang2
1
College of Engineering and Technology, Southwest University, Beibei, Chongqing, China
2
School of Computer and Information Science, Southwest University, Beibei, Chongqing, China
Abstract - Please Bellows is the flexible element of an
expansion joint used to absorb dimensional changes, and
the design of a bellows is complex. In this paper, the
optimization method was employed in the design of a U-
shaped metal bellows. A 4-variable 14-constraint
optimization model was built according to related standards
and practical engineering experience. Weight factors of
mass and flexibility in the objective function were set
according to importance of the objectives. Special strategies
were adopted to solve the multi-objective optimization
problem with mixed discrete and continuous variables. Case
study shows that the optimization model presented and
program developed can meet requirements of design of the
U-shaped metal bellows with high quality and efficiency.
Keywords: optimization design; multi-objective; modeling;
programming; metal bellows
1 Introduction
Bellows is the flexible element of an expansion joint
used to absorb dimensional changes, such as those caused
by thermal expansion or contraction of a pipeline, duct or
vessel. The design of a bellows is complex in that it
involves the evaluation of pressure capacity, stress due to
deflection, fatigue, and instability, etc. In many cases, the
design for a particular application involves a compromise
of conflicting requirements[1,2]. Optimization techniques
are widely used to achieve design goals of the complex
design problems with high quality and efficiency[3].
Bellows may be either U-shaped or -shaped (toroidal)
in cross section. The U-shaped bellows is superior for great
deflection but has a lower pressure capacity for the same
material thickness. Conversely, the -shaped bellows is
limited to small deflection but has a higher pressure
capacity. The use of external reinforcement of the U-shaped
can provide a combination of great deflection and high
internal pressure capacity, and the pressure capacity can
also be increased by the use of multi-ply construction or by
increasing the material thickness of the bellows. The U-
shaped bellows is mostly manufactured and used in
*
Correspondence author
industries, and the -shaped bellows has limited
application in case of high pressure and small deflection
requirements[4]. The design and optimization process of an
unreinforced U-shaped bellows was detailed in this study.
2 Problem description
The structure of unreinforced U-shaped bellows is
shown in Fig. 1. The bellows consists of one or more
convolutions, and the convolution is the smallest flexible
unit of a bellows. Lb , Lc , and Lt are bellows convoluted
length, tangent collar length, and tangent length,
respectively. An acceptable design of a bellows must meet
requirements of pressure capacity, fatigue life expectancy,
instability, spring rate per convolution, etc., and it is
complicated by the numerous variables involved such as
diameter, pitch, height, number of plies, and material
thickness. The basic design equations for the unreinforced
bellows are as follows.
BELLOWS
Lt
q
Lb Lc
COLLAR
w
nt
tc
Db
DIA
Figure 1 Structure of unreinforced U-shaped bellows.
Bellows circumferential membrane stress due to
pressure S 2 is:
PDm K r q
S2 = (1)
2 Ac
where, P is pressure; Dm is the mean diameter of bellows
convolutions, and Dm =Db + w + nt ; n is number of bellows
material plies of nominal thickness, t ; K r is circumferential
stress factor; q is convolution pitch; Ac is cross sectional
metal area of one convolution.
Bellows meridional membrane stress due to pressure
S3 is:
 Pw where, S y is yield strength at room temperature of the
S3 = (2)
2ntp actual bellows material after completion of bellows forming
where, w is convolution height; tp is bellows material and any applicable heat treatment; is inplane instability
stress interaction factor.
thickness for one ply, corrected for thinning during forming, Bellows theoretical axial elastic spring rate per
and tp =t Db Dm . convolution fiu is:
Bellows meridional bending stress due to pressure S 4 1.7 Dm Eb tp 3 n
is: f iu = (9)
w3Cf
2
P w 3 Optimization model description
S4 = Cp (3)
2n tp
Modeling is of prime importance for optimization of
where, Cp is factor used to relate U-shaped bellows bellows design. The mathematical model usually consists
convolution segment behavior to a simple strip beam. of variables, constraints, and objectives.
Bellows meridional membrane stress due to deflection For a design, all variables form a design domain,
S5 is: denoted by a vector X = [x1 , x2 , " , xn ]T . n is number of
Eb t p 2 e domain dimensions, and X can be considered as a point
S5 = (4)
2 w3 Cf in the n-dimensional design domain. Variables are often
where, Eb is modulus of elasticity at design temperature; e is
subjected to some constraints, denoted as gi (X ) 0 . i is
number of the constraints, and i = 1, 2, " , nc . Objectives
total equivalent axial movement per convolution; Cf is
factor used to relate U-shaped bellows convolution segment can be expressed by the objective function f (X ) based on
behavior to a simple strip beam. certain criteria. Then, the optimal design is a group of
Bellows meridional bending stress due to deflection variables having some values that make f (X ) minimum.
S6 is: 3.1 Variables
5 Eb tp e
S6 = (5) The variables of an optimization model must be the
3w2 Cd independent variables and be determined through
where, Cd is factor used to relate U-shaped bellows optimization. Number of variables need to be minimized on
convolution segment behavior to a simple strip beam. the premise of good optimization performance for purpose
Fatigue life N c , number of cycles to failure, is: of the decrease of model complexity.
a
The structure parameters of an unreinforced U-shaped
c bellows are as follows: mean diameter of bellows
Nc = (6)
St b convolutions Dm , inside diameter of bellows convolutions
where, a , b , and c are material and manufacturing Db , convolution height w , convolution pitch, mean radius
constants; S t is pressure, and S t =0.7 ( S3 + S 4 ) + ( S5 + S6 ) . of bellows convolutions rm , bellows nominal material
Limiting internal design pressure based on column thickness of one ply t , number of bellows material plies n ,
instability for single bellows (both ends rigidly supported) and number of convolutions in one bellows N , etc.
Psc is: Since bellows are compatible with pipeline, duct or
0.34 C f iu vessel linked, inside diameter of bellows convolutions Db is
Psc = (7) always defined according to the diameter of pipeline, duct
N 2q
or vessel. There is determined relationship between Db and
where, C is column instability pressure reduction factor
Dm , and Dm =Db + w + nt . Thus, Db and Dm are not
based on initial angular rotation; fiu is bellows theoretical
independent variables. In most cases, convolution pitch
initial axial elastic spring rate per convolution; N is number q and mean radius of bellows convolutions rm are preset by
of convolutions in one bellows.
manufacturer for simplicity of the molds for bellows
Limiting design pressure based on inplane instability
production. Therefore, the independent variables are
and local plasticity at temperature below the creep
convolution height w , bellows nominal material thickness
range Psi is:
of one ply t , number of bellows material plies n , and
1.3 Ac S y number of convolutions in one bellows N , then the variable
Psi = (8)
K r Dm q vector is:
 X = [x1 , x2 , x3 , x4 ]T = [ w, t , n, N ]T (10) where, P is design pressure.
3.2 Constraints 3.3 Objective function
The value of optimization objective depends on Bellows functions as the flexible element of an
variables, and there are some constraints acting on these expansion joint. Total equivalent axial movement per
variables. They can be either boundary constraint or convolution e , an index of flexibility evaluation for a
behavior constraint. bellows, can be selected as an objective for the optimization,
and the bigger flexibility, the better. From Eqs. (4) and (5),
3.2.1 Boundary constraint there is:
The constraint used to define the scope of variable ( S 5 +S 6 ) w 2
values or the relations between or among variables. e= (25)
The ratio w q has much influence on the performance Eb tp 5 ( 3Cd ) + tp ( 2wCf )
of a bellows, and it should be confined in the range of 0.6 to Bellows material is high quality austenitic stainless steel
1.6. Then: with strict requirements. On conditions of performance
g1 = 0.6 w q (11) warranty of bellows, decrease of the material use can result
in good benefit for the bellows production. Then, the total
g 2 = w q 1.6 (12)
mass of a bellows m can be another objective for the
There are some defined specifications for bellows optimization, and it is expressed as:
nominal material thickness of one ply t , and they can be
m=2 NntDm ( w 2rm + rm ) +2 ntL ( Db + nt ) (26)
any value of the following: 0.1, 0.2, 0.3, 0.4, 0.5, 0.8, 1.0,
1.2, 1.5, 2.0, 2.5, and 3.0mm. Then: where, L is bellows tangent length including collar,
g3 = 0.1 t (13) L = Lt + Lc .
g4 = t 3 (14) By means of evaluation function method, objective
function can be expressed as:
Number of bellows material plies n should be confined
in the range of 1 to 5, and number of convolutions in one m1
min f (X ) = 2 (27)
bellows N should be confined in the range of 1 to 15. Then: e
g5 = 1 n (15) where, 1 and 2 are weight factors of mass and flexibility,
g6 = n 5 (16) respectively, and set 1 = 1 , 2 = 1.1 according the
g7 = 1 N (17) importance of objectives.
g8 = N 15 (18) 4 Solving strategies
3.2.2 Behavior constraint Three are 4 independent variables and 14 constraints for
The constraint derived from requirements of design or the optimization problem. Variable of convolution height
performance of a bellows and expressed as function of w is a continuous variable, and variables of bellows
variables. nominal material thickness of one ply t , number of bellows
The stresses should be evaluated for pressure capacity material plies n , and number of convolutions in one
as follows: bellows N are discrete variables. It is a nonlinear
g9 = S2 Cwb Sab (19) optimization problem with mixed discrete and continuous
g10 = S3 + S 4 Cm Sab (below the creep range) (20) variables, and some strategies are employed to solve the
problem[5,6].
g11 = S3 + S 4 1.25 Sab (in the creep range) (21)
4.1 Strategies
where, Cwb is longitudinal weld joint efficiency factor;
Sab is allowable material stress at design temperature; Cm is 1) Initial discrete complex: For the n-dimensional
domain, the initial discrete point X (0) has boundary
material strength factor at temperature below the creep
conditions as follows:
range.
Fatigue life should be evaluated as: xi min xi(0) xi max (28)
g12 = N c N ab nf (22) where, i is the i th component of X (0) , and i =1, 2
", n ;
where, N ab is allowable number of cycles to failure; nf is xi min and xi max are the floor bound and ceiling bound of xi(0) ,
safety factor of fatigue, and nf =10 . respectively.
Instabilities should be evaluated as: Vertices of the initial discrete complex are defined as:
g13 = P Psc (23)
g14 = P Psi (24)
 xi(1) = xi( 0 ) RE 0 (33)
(j +1) If stop criterion cannot be met after search of k 1
xi = xi
(0)
(i j ) times, move all vertices except X ( L ) to X ( L ) some distance,
(j +1)
x j = x j min (29) often 1 3 of the distance between each vertex and X ( L ) .
(n + j +1)
xi = xi( 0 ) ( i j ) 5) Verification: The vertex X ( L ) that meets stop criterion
x(n + j +1) = x is an optimal vertex in the domain of neighborhood of X ( L ) ,
j j max which cannot guarantee it is the optimal vertex in the whole
totally, there are k vertices defined, and k = 2n + 1 . domain. Therefore, let X ( L ) be another initial discrete
2) One dimensional discrete search: Suppose X ( H ) is point X (0) . Repeat the optimization process mentioned
a vertex having the maximum value f (X ) among all the above, and get a new vertex X (*) that meets stop criterion
initial discrete complex vertices, and X ( C ) is the geometric until X (*) = X ( L ) . Then, the final optimal vertex X (*) can be
1 k (l ) obtained.
(C )
center of all vertices except X ( H ) , and xi = Xi ,
k 1 l =1 4.2 Program design
l = 1, 2, " , k ; l H . The search direction S is from X ( H ) According to strategies presented, a program is
to X , and S i = x x .
(C ) (C ) (H ) developed for solving the optimization model. The
i i
flowchart of the program is shown in figure 2.
Then, the new vertex after discrete search X ( R ) is:
START
xi(R ) = xi(H ) + Si (i = 1, 2, " , n)
(R ) (30)
xi = xi (i = 1, 2, " , p; p n)
(R )
INITIALIZATION

where, is increment factor; x is the discrete value

(R )
i

that is nearest to xi(R ) ; p is number of discrete variables. COSTUMER INPUT

3) Constraints on vertices and search: As the vertices

defined above are not subjected to constraints, some may INITIAL DISCRETE
VERTEX DEFINITION
locate in the areas out of feasible domain D . Define
effective objective function F (X ) as:
ONE-DIMENSIONAL
f ( X ), X D DISCRETE SEARCH
F ( X ) = M + C g ( X ), X D (31)
il
i NO MOVE VERTICES
SET X(L) TO X(0) STOP CRITERION
TO X(L) SOME
where, M is a constant much greater than f ( X ) ; C is a YES
constant; l = {i gi ( X ) > 0} . NO
VERIFICATION
Starting from a vertex X D along search direction S , YES

seek the minimum of C gi ( X ) . If C gi ( X ) 0 , then OUTPUT OPTIMAL

VERTEX & PERFORMANCE
il il

the new vertex is located in domain D , and effective

objective function of the vertex is F ( X ) = f ( X ) . STOP

4) Stop criterion: Define d i the difference of the Figure 2 Program flowchart

maximum and minimum discrete values of the i th variable,
namely:
5 Case study and discussions
di = ai bi (32) 5.1 Case study
where, ai = max { x ( j)
i }; bi = min { x ( j)
i } ; i = 1, 2, " ," , n , 1) Input: Costumer input and select of preset conditions
j = 1, 2, " ," , k . for the optimization are as follows:
Let i and i be the increments of continuous and Bellows type: unreinforced U-shaped bellows;
Support: both ends rigid support;
discrete variables, and preset integer E [n 2, n] , and n is Material: austenitic stainless steel 0Cr18Ni10Ti;
number of variables. If R is number of variables that Temperature during operation: 400 C;
satisfy di i for discrete variable or di i for continuous Pressure: 1.8 MPa;
variable, the stop criterion of the iteration process is: Applied axial movement in compression or extension:
20 mm;
Fatigue life: 1500 cycles;
Safe factor of fatigue life: 10;
Inside diameter: 300 mm;
Convolution pitch: 32 mm.
2) Output: Optimization results are as follows:
convolution height 24.1 mm; bellows nominal material
thickness of one ply 8 mm; number of bellows material
plies 3; number of convolutions in one bellows 8.
The performance data of the bellows from optimization
are as follows: bellows circumferential membrane stress due
to pressure 61.49 Mpa; bellows meridional membrane stress
due to pressure 9.43 Mpa; bellows meridional bending
stress due to pressure 163.57 Mpa; bellows meridional
membrane stress due to deflection 19.28 Mpa; bellows
meridional bending stress due to deflection 983.45 Mpa;
limiting internal design pressure based on column instability
for single bellows 2.1 Mpa; Limiting design pressure based
on inplane instability and local plasticity 1.8 Mpa; bellows
theoretical axial elastic spring rate per convolution 6535.89
N/mm; total equivalent axial movement per convolution
5.14 mm.
5.2 Discussions
Intensive understanding of design criteria, forming
methods and process flows is the basis of bellows design
and optimization.
While optimization modeling and solving, the
researcher should have practical engineering experience of
bellows design and analysis, and know how to deal with
common problems related to bellows design and use.
The weight factors of objectives for the objective
function have much influence on the output of the
optimization results, and they should be fully evaluated and
verified.
6 Conclusions
Optimization method was employed in the design of an
unreinforced U-shaped metal bellows. A 4-variable 14-
constraint optimization model was built based on Standards
of the Expansion Joint Manufactures Association, Inc., 9th
edition, and General Specification for Metal Bellows
Expansion Joint, GB/T 12777-2008. Weight factors of mass
and flexibility in the objective function were set according
to the importance of objectives. Some special strategies
were adopted to solve the optimization problem with mixed
discrete and continuous variables. Case study shows that
the optimization model presented and program developed
can meet the requirement of design of the unreinforced U-
shaped metal bellows with good quality and efficiency.
Acknowledgment
The study was supported by Fundamental Research
Funds for the Central Universities of China
XDJK2009B028, 2009C004. Correspondence author:
Mingjin Yang.
References
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Standards of the Expansion Joint Manufactures
Association, Inc., the 9th Edition. 2008. 1-4.43.
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Republic of China. General Specification for Metal
Bellows Expansion Joints. Beijing: Standards Press of
China. 2008. 1-36.
[3] Ye Yuanlie. Mechanical Optimization Theory &
Design. Beijing: China Metrology Publishing House. 2001.
1-88.
[4] Li Yongsheng, Li Jianguo. Practical Technology of
Bellows Expansion Joint Design, Manufacturing and
Installing. Beijing: Chemical Industry Press. 2000. 1-189.
[5]Zhang Weigang, Zhong Zhihua. Advanced Design
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