Abstract
The elastic compensation method proposed by Mackenzie and Boyle is used to estimate the upper and lower bound limit (collapse) loads for one-piece aluminium aerosol cans, which are thin-walled pressure vessels subjected to internal pressure loading. Elastic-plastic finite element predictions for yield and collapse pressures are found using axisymmetric models. However, it is shown that predictions for the elastic-plastic buckling of the vessel base require the use of a full three-dimensional model with a small unsymmetrical imperfection introduced. The finite element predictions for the internal pressure to cause complete failure via collapse fall within the upper and lower bounds. Hence the method, which involves only elastic analyses, can be used in place of complex elastic-plastic finite element analyses when upper and lower bound estimates are adequate for design purposes. Similarly, the lower bound value underpredicts the pressure at which first yield occurs.
1. Introduction
The design of pressure vessels
and related components is usually
based on a combination of finite element analysis and rules contained within
the appropriate codes of practice such as BS5500 [1] and ASME VIII [2] where
yielding is generally considered to be the upper bound. Post-yield design is
becoming more extensive, with techniques such as elastic-plastic finite element
analysis being used in order to study shakedown and ratchetting regimes as well
as collapse conditions. To avoid the added complexities of nonlinear analysis,
a limit load approach has been suggested [3–6]. The
lower limit is based on the lower-bound limit load theorem:
“If for a given load
, a
statically admissible stress field exists in which the stress nowhere exceeds
the yield stress of the material, then
is a lower bound limit
load.”
Correspondingly,
the upper limit is based on the upper-bound limit-load theorem:
“If, for a given load set, the rate
of dissipation of internal energy in a body is equal to the rate at which
external forces do work in any postulated mechanism of deformation, the applied
load set will be equal to or greater than the plastic collapse load.”
Direct
calculation of limit loads using upper and lower bound theories is very difficult
because it requires a statically admissible stress field and a kinematically
admissible strain field. In order to determine the equilibrium equations
between the external forces and internal stresses and the stress-strain
relationships, a complicated collapse solution is required. To avoid this,
several alternative approaches have been investigated; see review in [7]. The
reduced modulus method (see, e.g., [8]) has been modified [9] such that
(1)
the elastic-plastic solution is replaced by a series of
elastic solutions,
(2)
after each elastic computation, the modulus of
elasticity is reduced until the conditions of admissible stress and strain
fields, as lower and upper bound criteria, respectively, are satisfied.
This method has been further developed by Mackenzie and Boyle
[10] and Mackenzie et al. [11], who have presented an elastic compensation
method, where a series of elastic finite element analyses are used to predict a
converged solution, which meets either the lower or upper bound criteria. Applications
such as beams in bending and/or tension, nozzles in spheres, and torispherical
heads are considered. Gowhari-Anaraki and Adibi-Asl have used the method to
estimate upper and lower limit and shakedown loads for beam members and a thick
sphere in [12].
Hardy et al. [13] have used the method to estimate upper and
lower bounds for hollow tubes with axisymmetric internal projections under
axial loading. They found that this method could be used successfully to
determine upper and lower bounds for both limit and shakedown loading, when being compared with elastic-plastic finite element predictions.
Pham [14] has re-examined the
classical shakedown theorem due to Koiter [5] to include both shakedown and
nonshakedown conditions. The use of more sophisticated material behavior models
in shakedown analyses has also been investigated by
Weichert and Hachemi [15].
Aerosol cans, which are thin-walled pressure vessels with a complex
shape, are generally made of tin-plated steel or aluminium. In the former case,
the cans are normally constructed from three components; the base, the cylinder,
and the top, which are joined. Alternatively, aluminium cans are produced in
one piece from a cylindrical slug, using the “back extrusion” process. Most
cans have bases that curve inwards and this shape strengthens the structure of
the can. The inverted base design is an inherent safety feature as it provides
a natural pressure release mechanism in the event of a pressure overload, with
“dome reversal” (which is a form of elastic-plastic buckling) of the base
occurring. This sudden change in geometry (a) results in an immediate fall in
pressure and (b) provides a visual indication, since the can is no longer
stable. In order for this pressure release mechanism to be effective, the
design must be such that “dome reversal” occurs at a pressure lower than the
burst pressure.
In this paper, the elastic compensation method is used to estimate
the upper and lower bound limit loads for aluminium aerosol cans subjected to
internal pressure loading and the results are compared with elastic and
elastic-plastic finite element predictions of yield and collapse pressures.
This relatively straight-forward geometry has been used to further investigate
the validity of the elastic compensation method.
Seshadri and Kizhatil [16]
have suggested that if the procedure cannot be verified for simple components,
it is unsafe to use it for more complex design.
Initially, the wall of the can is assumed to be of constant
thickness and results for six thickness values are presented using axisymmetric
finite element models. A realistic thickness profile is also used in a seventh
three-dimensional model. The results demonstrate the inability of the
axisymmetric models to predict elastic-plastic buckling and the seventh
three-dimensional model, with initial imperfection, is used in order to
replicate this buckling mechanism.
2. Elastic Compensation Method
The aim of the method, as described in [10, 11], is to
systematically redistribute the predicted stress field, while still remaining
statically admissible, by carrying
out an iterative elastic analysis and modifying the local elastic modulus at
each stage. In the resulting linear elastic solution, the displacement and
strain fields remain compatible and describe a geometrically possible
deformation mode. Full
details of the procedure are provided in [10, 11, 13] and a brief review of the
method is given here.
An initial elastic finite element analysis is performed with an
arbitrary load set (e.g.,
), using the true modulus of elasticity
for the material,
. This is taken to be the zeroth iteration in a
series of linear elastic analyses. In each of the subsequent analyses, the
elastic modulus of each element is modified according to the equation
(1)where subscript “
” is the current iteration number,
is a limiting value of stress, and
is some characteristic stress
within the element. It is suggested that this limiting stress is related to the
material yield stress,
, by
(2)where αis an
arbitrary constant between 0 and 1 (2/3 being found to
provide suitable convergence). It is also suggested that the characteristic
stress is the maximum (unaveraged) nodal equivalent stress associated with the
element calculated in the previous iteration, defined as
. Nodal values are selected, in
preference to integration point values, because they are the direct output from
the elastic analysis and can be easily extracted by the FORTRAN interface
program that has been written, as discussed later. Hence the iteration on
element modulus of elasticity becomes
(3)The iterative procedure redistributes the stresses in the component
and, over a number of iterations, the net effect is to decrease the maximum
stress in the model to reach a converged constant value,
.
2.1. Application to Lower Bound Limit Load
The lower bound limit load is calculated by applying the lower bound
limit load theorem. The converged elastic compensation solution satisfies the
first requirement of the lower bound theorem in that it is statically
admissible. Because the solution is linear elastic, there is a linear
relationship between stress and applied load. A lower bound load,
,
can therefore be established as the load required to give a maximum (nodal
equivalent) stress in the component/structure that is equal to the uniaxial
yield strength of the material,
. In a previous work
(see [10]), it is argued that
this lower bound load can be found from the proportionality relationship for
the converged elastic solution (although other methods are possible), and hence
for the worst point in the model and using this proportionality relationship:
(4) hence
(5)The applied load set,
, is not restricted to single
loads and may represent multiple forces, moments, pressure, and so forth, in
the form of proportional loading.
2.2. Application to Upper Bound Limit Load
The upper bound limit load theorem for a complete plastic collapse
solution can be expressed as (see [17])
(6)where
is the rate of dissipation of energy per unit
volume,
is the set of equilibrium external loads, and
is the compatible set of displacement rates,
which requires details of that complete plastic collapse solution.
Alternatively, an upper bound solution can be found when an
incomplete or partial plastic collapse solution is available [11] and
(6) can
be rewritten in the form
(7)where the asterisk denotes an incomplete solution (i.e., a
geometrically possible mode of deformation in which the stress field is not
necessarily defined).
For this incomplete solution, compatible sets of displacements and
strain increments are required and an iterative elastic finite element
analysis, employing the elastic compensation method, will provide such
information. However, the finite element predictions required to obtain the
left-hand side of (7) are not always readily available. However, since the
solutions are elastic, the elastic strain energy increment can be substituted, that
is,
(8)where
and
are the elastically calculated stress and
strain increment, respectively. Also, the increment of energy dissipation per
unit volume for an elastic-perfectly plastic material, using the von-Mises
yield criterion, can be expressed as [11]
(9)where
are the three principal strain
rates.
Equation (8) can be
rewritten in simple form as
and, as
shown in Figure 1, the dissipation energy,
, is linearly related to the applied load whereas the strain
energy,
, varies with the
square of the load. Furthermore, the intersection of the two lines represents
the upper bound on the limit load.
Figure 1:
Variation in strain energy and dissipation energy with applied load, used in
the calculation of the upper bound limit load.
The upper bound limit load is therefore obtained using predictions from
the converged elastic compensation finite element solution with the arbitrary
load set,
, that is,
(10) and because the
solutions are elastic:
(11) Equating
and
at the upper bound limit load,
, gives
(12)where
and
are found from the
converged elastic compensation finite element solution.
2.3. Method of Approach Using Finite Element Analysis
The procedure used in this approach is as follows [13].
(a)
Zeroth iteration. The initial elastic analysis is carried out
with an arbitrary pressure,
, using
throughout.
(b)
th iteration
(c)
Converged solution. This occurs when
becomes constant.
2.4. Notes
(1) Strain energy values are obtained directly from the finite
element program output file. The dissipation energy for each element is
obtained from the three principal strain rates, the yield stress, and the
element volume, using a version of (9) based on absolute values, not rates. A
simple FORTRAN program was written to perform this calculation.
(2) The procedure in (i) to (iv) above is time consuming and prone to
error, when performed manually. A FORTRAN program was written to perform these
tasks automatically.
3. Finite Element Analysis (Constant Thickness Model)
A typical basic finite element model, made up
of six
“substructures”, for a can section that has a constant thickness of 1 mm is
shown in Figure 2. Since the methodology involves an iterative finite element
procedure, it was necessary to choose a mesh that meets both the condition of
convergence and that of economy of the solution. A preliminary investigation,
starting with a coarse mesh of 34 eight-noded axisymmetric elements (2
through-thickness), was undertaken in order to establish a suitable mesh for
which mesh convergence had been reached. For the elastic compensation method
analysis, 296 eight-noded, axisymmetric elements
were generated manually from the basic mesh in Figure 2. On the basis
of
preliminary predictions, the cylindrical section was made long enough to ensure
that a uniform stress was reached away from the discontinuities. The model is
subjected to uniform internal pressure loading.
Figure 2: Basic
axisymmetric finite element model for can with constant thickness.
Finite element predictions have been obtained using the elastic (for
compensation method) and large displacement elastic-plastic (for yield,
elastic-plastic buckling and collapse) facilities of the ELFEN suite of
programs [18]. Aluminium material property values for the true modulus of
elasticity,
, yield stress,
, and Poisson’s ratio, ν, of 68.3 GPa, 100 MPa, and 0.3, respectively,
were assumed. For the elastic-plastic analysis, an elastic-perfectly-plastic
material model was assumed (for consistency with the plastic limit load
theorem). In the elastic compensation analysis, an arbitrary pressure of 0.1 MPa has been used.
3.1. Elastic Analysis
Figure 3 shows the
von-Mises equivalent stress
contour plot for the initial elastic solution (i.e., zeroth
iteration in the elastic compensation method).
Regions of above-average stress occur in the transition region between cylinder
and base and at the base centre. By scaling up the results shown in Figure 3,
where the maximum predicted stress is 13.25 MPa, an internal pressure at which
first yield occurs was found to be 0.75 MPa.
Figure 3: Equivalent stress contour plot for the
zeroth iteration of the elastic compensation method with

mm.
The iterative procedure described above has then
been employed (with the aid of a FORTRAN program) and the modulus of elasticity
in each element modified according to (3). The maximum equivalent stress at the
end of each subsequent iteration is shown in Figure 4, from which it is clear
that a converged solution occurs after 4 iterations with
MPa. The
elastic compensation method may, depending on the characteristic stress
selected, cause the maximum stress to increase or decrease, but by careful
selection, it is generally found that over a number of iterations there will be
a net decrease in maximum stress with respect to the initial elastic solution.
Figure 4: Maximum
equivalent stress at the end of each iteration for

mm.
The steady-state (converged) equivalent
stress contour plot is shown in Figure 5. A redistribution of stress has
occurred with an initial stress range of 0.22–13.25 MPa (see
Figure 3) reducing to 0.02–10.72 MPa. It is also apparent that the stress
discontinuities at element boundaries have become more pronounced since the
values of elastic modulus can now significantly vary from element to element. From
(5), it follows that the predicted value of
is 0.93 MPa.
Figure 5: Steady
state equivalent stress contour plot for

mm.
In order to obtain an upper bound estimate, values of dissipation
energy and strain energy, for the converged solution, are required. A FORTRAN
program was written to extract the stress and strain predictions from ELFEN and
from which the dissipation energy was derived, using the method described
earlier. Having
done this and using (6) and (12), the predicted value of
is 2.20 MPa.
This whole process was repeated for constant thickness models of
0.4, 0.6, 0.8, 1.2, and 1.4 mm (which represents the variation in thickness
seen in actual cans), using the same mesh in each case. The resulting upper and
lower bound pressures are summarized in Table 1, together with the yield
pressures.
Table 1: Upper and lower bound pressures and
elastic-plastic finite element predictions of yield and collapse pressures.
3.2. Elastic-Plastic Analysis
Since the internal pressure is a function of the
volume, any large deformation (i.e., elastic-plastic buckling) will reduce the
pressure inside the can. This cannot be easily modeled, therefore it is assumed
that the pressure is increased very slowly and that, in practice, the pressurization
pump will quickly restore the pressure at the point of buckling.
The basic mesh shown in Figure 1 was then used to develop a more
refined mesh of eight-noded, axisymmetric elements and plastic collapse was
predicted to occur at a pressure of 1.59 MPa,
for which the equivalent stress distribution is shown in Figure 6.
Figure 6
also shows the exaggerated displaced shape and it is clear that a plastic hinge
has occurred close to the intersection between the cylindrical section and the
start of the base. With further increasing pressure, convergence did not occur
thus suggesting the onset of “collapse” of the model. It should also be noted
that a maximum stress slightly higher than 100 MPa is predicted due to the
tolerance on the convergence criteria within the iterative elastic-plastic
procedure [18].
Figure 6:
Equivalent stress contour plot for

MPa and

mm.
This procedure was repeated for constant thickness values of 0.4,
0.6, 0.8, 1.2, and 1.4 mm, using the mesh design in
Figure 6 and the predicted
plastic collapse pressures are also summarized in Table 1 and the full set of
results is presented in Figure 7. These results will be discussed later.
Figure 7:
Comparison between upper and lower bound pressure estimates and finite element
predictions of yield and collapse pressure, as a function of can wall thickness
for constant thickness models.
4. Finite Element Analysis (Variable Thickness Model)
The analyses discussed above, although useful in studying the
mechanisms involved and the accuracy of the upper and lower bound estimates,
are not truly representative in two respects:
(a)
the actual thickness profile is more complex (i.e., nonuniform);
(b)
in practice, there is a clear distinction between the
elastic-plastic buckling and collapse pressures.
A realistic profile was determined by cutting several cans along
their axes and using a micrometer to measure thickness. Based on these
experimental measurements, the thickness profile varies from a minimum of ~0.32 mm in the cylinder to between ~0.70 and ~1.31 mm in the base, with the maximum
thickness being at the centre of the base. A typical basic finite element
model, using eight “substructures”, is shown in
Figure 8. The thickness profile
of an actual can is determined by both the punch and die geometry and the
pressure requirements for “dome reversal” and collapse. Current investigations
are being undertaken to optimize this profile and work on the modeling of the
extrusion process has been reported elsewhere [19].
Figure 8: Basic
axisymmetric finite element model for can with variable thickness.
The finite element program and material properties discussed earlier
have also been used for this analysis.
4.1. Elastic Analysis
A finite element mesh containing 296 eight-noded,
axisymmetric elements was generated manually from the basic geometry of
Figure 8. The iterative procedure previously
described for constant thickness models was repeated using this variable
thickness model. A steady-state maximum
equivalent stress of 12.4 MPa was predicted and from (5) the predicted value of
is 0.81 MPa.
Values for the steady state dissipation and strain energies were
obtained using the procedure described above, and using (6) and (12) the
predicted value of
is 2.59 MPa.
4.2. Elastic-Plastic Analysis
Experimental evidence suggests a slightly unsymmetrical buckling
mode, due to minor radial variations in profile, which cannot be predicted
using an axisymmetric model. Therefore a full three-dimensional model was
developed and elastic-plastic buckling of the base replicated by the
introduction of a small imperfection in a similar way to that reported by
Robotham et al. [20] for plain shafts in torsion. From a preliminary eigenvalue
analysis (i.e., lowest mode) and supported by experimental evidence, nine
surface nodes along a radial line out from the center were moved out axially by
a distance equal to ~5% of the wall thickness at that point. This provided a
bifurcation point and enabled the buckling mode to be investigated. Robotham et al. [20] showed that imperfections in the range 1–10% produced similar
results.
Using the finite element model shown in
Figure 9, made up of 5165
six-noded three-dimensional wedge elements and generated automatically from the
cross-section shown in Figure 8, finite element predictions of yield and
elastic-plastic buckling pressures of 1.20 and 1.53 MPa, respectively, were predicted. Unlike the axisymmetric model, this model is
able to resist a further increase in pressure, prior to collapse and the
predicted collapse pressure (above which convergence was not achieved) is 2.02 MPa. The predicted elastic-plastic buckling mode, at a pressure of 1.53 MPa, is
shown in Figure 10. Again, due to the tolerance on the convergence criteria,
equivalent stresses of up to 7% higher than the yield stress are predicted. The
predicted shape is very similar to that seen in experimental burst testing, for
which a typical failure is shown in Figure 11. This will be reported in a later
paper.
Figure 9:
Three-dimensional finite element model for can with variable thickness.
Figure 10: Elastic-plastic buckling equivalent stress contour plot for variable thickness
model at

MPa.
Figure 11: Burst aerosol can showing the
elastic-plastic buckling mode.
5. Discussion of Results
The application of the elastic compensation method to upper and
lower bound calculations is relatively straight-forward. However, it is an
iterative, time-consuming process and so a simple FORTRAN user interface with
the finite element program has been developed in order to automatically modify
the values of Young’s modulus for each element after each iteration and to
monitor convergence. The upper bound estimate is then easily evaluated from the
converged solution. The lower bound estimate, however, also requires the strain
energy and dissipation energy for the converged solution. Whereas some finite
element programs provide details of strain energy, the dissipation energy may
not be readily available and a further FORTRAN program to obtain this value
from the finite element predictions of principal strains has been developed.
The paper presents an interesting deviation from the usual
application of the elastic compensation method. It is recognized that
elastic-plastic buckling problems of this type, involving large displacements,
are not strictly suited to analysis via the elastic compensation method, which
is based on small strain theory. This is particularly true for the
geometrically nonlinear collapse mechanism associated with dome reversal.
However, the results suggest that there is some merit in carrying out such an
analysis to provide an approximate solution at the early design stage and provides
additional confidence in the method.
5.1. Constant Thickness Axisymmetric Models
The results presented in Figure 7 show that the predicted collapse
pressures lie between the upper and lower bound estimates and this provides a
degree of confidence in these approximate methods. However, the range between
the upper bound and lower bound is rather large (in the worst case, +71% to
40% of the predicted collapse pressure). Furthermore, the lower bound is
always greater than the yield stress. This limits the use of these approximate
methods for this type of geometry and loading to collapse pressure estimates.
Nevertheless, the elastic compensation method is useful since it only requires
elastic analyses.
Although axisymmetric models can provide some useful information on
the elastic and elastic-plastic behavior of such components under internal
pressure, the practical issue of dome reversal cannot be investigated and a
full three-dimensional analysis is necessary.
5.2. Variable Thickness Models
A variable thickness model, which reflects the true thickness
profile of measured cans, has been used and it is clear that there is a
significant difference between the thickness of the cylindrical section (0.32 mm minimum) and that of the base (1.31 mm maximum). In this case, although the axisymmetric model
can be used in the elastic compensation method, a full three-dimensional model
was used to predict elastic-plastic buckling and plastic collapse.
Again, the upper pressure bound estimate of 2.59 MPa is 28% higher
than the predicted plastic collapse pressure of 2.02 MPa, which further
demonstrates the usefulness of the elastic compensation method. However, the
lower bound estimate of 0.81 MPa is 33% lower than the yield pressure of 1.20 MPa, in a similar way to the predictions for the constant thickness models.
By comparing variable thickness results with those for constant
thickness models, it is apparent that the upper and lower bound estimates for
the variable thickness model fall between the 0.8 to 1.2 mm constant thickness
results, which might be considered to be reasonable since the region with the
highest stress concentration and where buckling ultimately occurs (i.e., the
discontinuity between cylinder and base) has a thickness varying between 0.7
and 1.3 mm.
6. Conclusions
(1) In all the cases considered, the elastic-plastic predictions of
plastic collapse pressure fall within the upper and lower bound estimates and
so the upper bound approach, which is far less time-consuming and has less
computational complexity, provides a useful estimate of collapse pressure. On
the other hand, the lower bound estimate cannot be used safely when “design to
avoid yielding” is the criterion. It is suggested that this is due to the
complexity of the profile and the resulting nonuniform stress distribution.
(2) The elastic compensation method provides a straight-forward and
useful approach, without the need for complex elastic-plastic analysis, which
requires knowledge and modeling of the post-yield nonlinear material behavior.
(3) Whereas the lower bound limit load can be obtained directly from
the converged elastic solution, additional programming may be needed for the
upper bound method in order to calculate dissipation energy from the finite
element predictions.
(4) The true thickness profile of a can is far from constant and a
direct function of the extrusion process and tooling geometry. Experimental
measurements suggest a minimum thickness in the cylindrical section of ~0.32 mm
and a maximum base thickness of ~1.31 mm. Although the constant thickness
models have provided a useful insight into the mechanisms of failure and the
usefulness of the elastic compensation method, accurate predictions can only be
achieved using a variable thickness model.
(5) The axisymmetric models and three-dimensional models with
rotational symmetry can be used to predict initial yield and plastic collapse
pressures. However, they are unable to differentiate between elastic-plastic
buckling (or dome reversal) and total collapse. For this reason, Robotham et al.’s
method [20] of introducing slight geometric imperfections has been used
successfully to identify dome reversal.
Notations
: |
Dissipation
energy |
: |
Modulus
of elasticity for iteration  |
: |
True
modulus of elasticity |
: |
Internal pressure |
: |
Load (set) |
: |
Arbitrary
load (set) |
: |
Can thickness |
: |
Displacement (set
of) |
: |
Strain energy |
: |
Volume |
|
Constants |
|
ε: |
Strain |
|
ν: |
Poisson’s
ratio |
: |
Stress |
: |
Converged
stress. |
Subscripts
| char: |
Characteristic |
: |
Associated with
arbitrary load (set)  |
: |
Elastic |
: |
Lower
bound, limiting |
: |
Upper bound |
: |
Yield. |
Superscripts
|
Rate |
| *: |
An incomplete solution. |
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