Optimization of Design Parameters of Bellows Using ...

International Review of Mechanical Engineering (IREME), Vol. 11, N. 10 ISSN 1970-8734 October 2017 Special Issue on “ICMESCoE-2017”

Optimization of Design Parameters of Bellows Using Taguchi Method S. K. Makke, A. A. Keste, S. H. Gawande Abstract – Bellows is one of the key sections in the expansion joint and has the ability to assimilate uniform and non-uniform expansion and contraction of the system. Bellows require high quality and incredible adaptability which can be accomplished by extraordinary design and fitting assembling methodology. Expansion joints are made to work in the elastic stress range. This may lead to induction of fatigue in bellows after a limited number of development cycles. The main objective of this paper is to find the optimal level of parameters and develop a regression model for the output variable. Taguchi’s L16 orthogonal array is applied for reducing the number of runs and time for experiment. Statistical techniques analysis of variance (ANOVA), signal-tonoise (S/N) ratio, graphical main effect and interaction plots have been used to study the effects of various parameters on the number of cycles. The optimum parametric condition is obtained using the Taguchi method. Copyright © 2017 Praise Worthy Prize S.r.l. - All rights reserved.

Keywords: Bellows, Taguchi, ANOVA, Pressure, Thickness of Ply, Convolution Depth, Regression Analysis

I.

Using direct axis symmetric shell parts, the parametric examination is driven. Limited component investigation is finished utilizing the business code. Bellows molding technique is used in the wake of assessing powerful parameters [6], whereas the results obtained by finite element method (FEM) show a closed match with the analytical analysis in [7] utilizing a business FEM code, ABAQUS Explicit, to repeat the fabricating technique of metal bellows. Kang, et al. [8] worked on framing of various conditions of tubular bellows utilizing a hydroforming strategy. In view of the examination, another non-destructive extend test is proposed with which unique life evaluations can be refined, as proposed by Subramanian et al. [9]. The advanced state of the bellows is required to give great rules to the useful designs proposed by Jinbong, et al. [10]. As per Tingxin, et al. [11] bellows have longer exhaustion time, more grounded capacity to oppose internal pressure instability. The outcomes demonstrated that the presence of destructive medium accelerates both split start and propagation rates and diminishes the failure life of the expansion joints [12]. It was found that, by cycling pressure on the hose and applying a pressure significantly greater than the yield capacities of the hose, this blend of yielding and cycling brought a burst failure [13], whereas the bellows failed at 26770 cycles, after producing three circumferential cracks near the upper jig and lower flange [14]. First, AE was detected at 21782 cycles. This timing was 1500 cycles earlier than the first circumferential crack near the upper jig, as observed by the video camera. AE count increased after 24000 cycles, at which large third circumferential cracks were produced near the lower flange. Furthermore, as per literature, it is seen that many researchers uses Taguchi

Introduction

Metal expansion joints, which are basically called compensators, are repaying segments for warm development and relative advancement in compartments, machines and pipelines. They involve just one metal bellows, connectors at both completes and tie shafts that rely upon the application. They are isolated by three fundamental sorts of advancement: expansion, axial and angular joints. Many researchers worked in the area of the expansion joint for shell and tube heat exchanger. By performing industrial survey (in particular at Alfa Laval India Ltd, Pune, India) their work was represented and careful reviewed through earlier published works in journal papers and specialized technical reports. Many formulae of bellows can be established from ASME code [1]. Many bellows formulae can be established from ASME code [1], whereas highly extensive and comprehensively recognized guidelines on bellows configuration are provided by Expansion Joint Manufactures Association [EJMA] [2]. Shaikh, et al. [3] performed many pilot tests for examination of AM350 steel bellows. As bellows is exposed to marine atmosphere for more than 13 years, it leads to pitting effect, hence the determination of the dynamic characteristics of beam finite elements by manipulating certain parameters on commercial software was done by Browman, et al. [4]. In comparison with semi- analytical methods, it has the potential of considering axial, bending and torsion degrees of freedom at the same time, and rest is modeled by finite elements. The effect of the elliptic level of Ω-shaped bellows toroid on its stresses is looked by Li [5]. Copyright © 2017 Praise Worthy Prize S.r.l. - All rights reserved

https://doi.org/10.15866/ireme.v11i10.13179

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S. K. Makke, A. A. Keste, S. H. Gawande

(DOE) method to study the effects of biodiesel on diesel engine combustion and pollutant emissions as well as vibrations and noise aspects. Many researchers apply various optimization techniques to find the optimum value of operating parameters for better output [16]-[20]. Again, it is observed that there is scarcity of literature on optimized fatigue life on operating parameters viz, pressure, thickness of ply, and convolution depth of metal expansion joint (Bellows) (as shown in Fig. 1) with the application of different statistical techniques. The ANOVA method is used to determine the rank of different parameters. Moreover, the regression equation directly provides the value of the number of cycles.

find out the most influencing parameter affecting this response. TABLE II DESIGN OF EXPERIMENT COMBINATIONS Pressure Thickness Convolution (N/mm2) (mm) depth (mm) 0.05 0.280 7 0.05 0.290 10 0.05 0.3 9 0.05 0.31 8 0.1 0.280 8 0.1 0.290 7 0.1 0.3 10 0.1 0.31 9 0.15 0.280 9 0.15 0.290 10 0.15 0.3 7 0.15 0.31 8 0.2 0.280 10 0.2 0.290 9 0.2 0.3 8 0.2 0.31 7

No. of run 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

No. of cycles 87779 122066 48058 16891 23572 73969 95796 39464 20122 94446 63008 39477 91382 42302 16532 54173

M ain Effects Plot for No. of cycles Data Means Pressure

Thickness

Covolution Depth

100000 90000 80000

Mean

70000

Fig. 1. Metal Expansion Bellows

60000 50000

II.

Design of Experiments

40000 30000

For DOE, the parameters selected are those that affect the fatigue life of the bellows. These parameters are pressure, thickness of ply, convolution depth, operating temperature, number of plies, convolution pitch and shape of convolution. The Taguchi method was used to optimize these bellows operating parameters. L16 array was used with four levels of each parameter. The range independent operating parameters selected for the problem are pressure 0.05 ≤0.1≤0.15≤0.2, thickness of ply 0.280