BELLOWS DESIGN

The design of a bellows is complex in that it involves an evaluation of pressure capacity,

stress due to deflection, fatigue life, spring forces and instability (squirm). Instability is
unique in that users do not generally recognize that internal pressure can cause a bellows to
buckle in a manner similar to a column subjected to compressive loading. The
determination of an acceptable
design is further complicated by the numerous variables involved such as diameter, material
thickness, pitch. height, number of plies, method of reinforcement, manufacturing
technique, material type, and beat treatment. In many cases, the design for a particular
application will
involve a compromise of conflicting requirements. For example: high pressure necessitates
a bellows constructed of thick material while low forces require a thinner material.
Several noteworthy theoretical stress analyses of bellows have been developed, each of
which has inherent limitations. The analyses are normally based on assumptions which
approximately predict the true behavior of a bellows. The assumptions usually consist of
an idealized bellows configuration, a uniform thickness, a homogeneous and isotropic
material, and elastic behavior. These assumptions are not precisely correct for most
applications. A bellows usually operates in the plastic stress region and cold work, due to
forming, alters the mechanical properties of the material. A few investigators have
employed computerized analysis techniques to more
accurately consider the effect of thickness and shape variations as well as plasticity. This
procedure is obviously more complex than a simple elastic analysis and yet does not fully
solve the design problem in the absence of experimental verification.
The major stresses in a bellows result from the effects of pressure and deflection. Normally
the deflection stresses are higher than the pressure stresses, are generally above the yield
point of the bellows material, and are meridional (longitudinal) in direction.
Pressure produces circumferential (hoop) membrane stress in the bellows tangent and
convolutions. Both meridional membrane and bending stresses are also produced
in the convolutions by pressure.
A toroidal cross section is superior for high pressure capacity, but is limited to small
deflections. Conversely, a U-shaped cross section permits greater deflection but has a lower
pressure capacity for the same material thickness. One method of providing a combination of
high internal
pressure capacity and large deflection is the use of external reinforcement of the U-shaped
bellows. The external reinforcement offers circumferential restraint and supports the root
radius against collapse from internal pressure loading. The pressure capacity of a bellows
can also be increased by the use of multi-ply construction or by increasing the thickness of
the bellows:
however, the latter can significantly reduce the bellows fatigue life.
Fatigue life of a bellows is influenced by the combined stress range induced by pressure and
deflection. The fatigue life of the bellows for a given configuration and material thickness
will be a function of the imposed pressure and deflection.
The spring forces exerted by a deflected bellows may be critical. A deep convolution with a
thin wall will deflect with less force than a shallow convolution with a thick wall.
A bellows design should always be based on the actual bellows metal temperature
expected during operation. This temperature may be less than the media temperature.
It should be understood that bellows geometry as well as forming methods vary widely

throughout the industry with no one configuration and forming method necessarily
superior for all design conditions.