EXPANSION BELLOWS CALCULATION PER AD2000 MERKBLATT CHAPTER B13

INPUT GEOMETRY:
Nominal bellows diameter: d = 399.90 mm d/h = 6.15
Bellows nominal thickness: s = 6.50 mm r/h = 0.38
Bellows height: h= 65.00 mm s/h = 0.10
Bellows mean radius: r= 25.00 mm
Bellows straight flange: b= 25.00 mm Check 3 < d/h < 100 OK
Number of convolutions: z= 2.00 Check 0.1 < r/h < 0.5 OK
Bellows pitch: l= 100.00 mm Check 0.018 < s/h < 0.1 OK
Mean diameter: dm = 464.90 mm Check b > max ( 3s ; 10 ; 0.25 √d s ) OK
Inside bellows diameter: di = 393.40 mm Check b < 0.5 √ d s OK

CALCULATION OF STRESS INTENSITIES:

d/h (1) = 5.00 d/h (2) 7.00
R(p) (2) 3.52 r/h (2) 0.35 R(p) (2) 3.94 r/h (2) 0.35
R(p) (1) 3.42 r/h (1) 0.40 R(p) (1) 3.92 r/h (1) 0.40
FACTOR L = (Y2-Y1) / (X2-X1) = -2.000 FACTOR L = (Y2-Y1) / (X2-X1) = -0.400
r/h actual: 0.38 r/h actual: 0.38
R(p) for d/h (1) actual: 3.45 R(p) for d/h (2) actual: 3.93

R(w) (2) 331.20 r/h (2) 0.35 R(w) (2) 328.20 r/h (2) 0.35
R(w) (1) 314.10 r/h (1) 0.40 R(w) (1) 312.80 r/h (1) 0.40
FACTOR L = (Y2-Y1) / (X2-X1) = -342.000 FACTOR L = (Y2-Y1) / (X2-X1) = -308.000
r/h actual: 0.38 r/h actual: 0.38
R(w) for d/h (1) actual: 319.36 R(w) for d/h (2) actual: 317.54

R(cw) (2) 74.94 r/h (2) 0.35 R(cw) (2) 67.50 r/h (2) 0.35
R(cw) (1) 82.66 r/h (1) 0.40 R(cw) (1) 70.70 r/h (1) 0.40
FACTOR L = (Y2-Y1) / (X2-X1) = 154.400 FACTOR L = (Y2-Y1) / (X2-X1) = 64.000
r/h actual: 0.38 r/h actual: 0.38
R(cw) for d/h (1) actual: 80.28 R(cw) for d/h (2) actual: 69.72

d/h actual: 6.15

R(p) (2) 3.93 d/h (2) 7.00 R(w) (2) 317.54 d/h (2) 7.00
R(p) (1) 3.45 d/h (1) 5.00 R(w) (1) 319.36 d/h (1) 5.00
FACTOR L = (Y2-Y1) / (X2-X1) = 0.238 FACTOR L = (Y2-Y1) / (X2-X1) = -0.912
d/h actual: 6.15 d/h actual: 6.15
R(p) for d/h actual: 3.72 R(w) for d/h actual: 318.31

R(cw) (2) 69.72 d/h (2) 7.00

R(cw) (1) 80.28 d/h (1) 5.00
FACTOR L = (Y2-Y1) / (X2-X1) = -5.285
r/h actual: 6.15
R(cw) for d/h actual: 74.20

INPUT DESIGN DATA:

Design pressure: p= 52.00 barg Material: 1.4541 (SS 321)
Design temperature: T= 425.00 C Stress: K= 154.00 Mpa
Elasticity at temperature: E= 167000.00 Mpa Poisson's: v= 0.30
Elasticity at ambient: E20 = 195000.00 Mpa Fatigue: N= 5000.00 cycles
Single bellow discplacem.: w = 2.50 mm Weld factor: v = 1.00

CALCULATION RESULTS:
1) Check against static pressure:
σv(p) = R(p) * p = 193.68 Mpa n1 = 1.55 Check σv(p) < n K / Svp
n K / Svp = 198.92 Mpa Svp = 1.20 OK
2) Check circumferential stress:
σum = (d+h) l p / 40 s ( 1.14 r + h ) v = 99.44 Mpa Check σum < Κ / Sum
Sum = 1.50
K / Sum = 102.67 Mpa OK
3) Loading due to axial movement:
σv(w) = 2.4 * E * R(w) * w / 10000 h = 490.69 Mpa
cw = 0.15 (d+h) E R(cw) / 10000 = 86405.74 N/mm

4) Instability due to internal pressure:

s* = s √ di / dm = 5.98 mm Factor cf (appendix 1): cf = 1.679
Factor C3 = l / 2h = 0.77 Factor cp (appendix 1): cp = 0.561
Factor C4 = l / 2.2 √ dm s* 0.86 Factor δ = Α cp / 3 dm l (h /s*)² = 0.532
A = (l (π-2)/2 + 2h ) s* = 1118.13 mm Factor β = 1+2δ² + √ 1 - 2δ² + 4δ ) = 4
2.434
For bellows in the formed state (cold work hardened)
sθ = ln ( 1 + 2 h / di ) = 0.286 mm For hydraulic or similar methods with 100% outward forming.
sb = ln ( 1 +s / ( 2r + s)) = 0.109 mm sd = 1.04 * √ sθ² + sb² = 0.318 mm
Consolidation factor: Kd = 2.00 Re* = Kd * K = 308.00 Mpa
Ps,c = 3.4 π² 0.5 / (1-v²) (d+h) E / z² l cf (s*/h)³ = 1657.32 Bar Check p < Ps,c OK
Ps,ι = 10(π-2) Α Re* / dm l √ β = 54.12 Bar Check p < Ps,ι OK

5) Check for fatigue:

Factor C (from table 1): 0.105 B = max ( σv(p) / n Svp K ; σum / Κ / Sum ) = 0.974
Δσvges = Δσv(p) + Δσv(w) = 684.37 Mpa Δσvges / K = 4.444
Safety factor f2 = 1.354 Safety factor f1 = 1.00 E20/E = 1.168
Total stress range: 2 ε,ages = Δσvges f2 f1 100 / E * (E20/E) = 0.65 SL = 2.00
Allowable number of cycles: Nzul = ( 10 / 2 ε,ages ) 3.45
/ SL = 6298.96 Check N < Nzul OK