Abstract
In pressurized heavy water reactors, pressure tube to end fitting rolled joint is crucial for safe operation. The joint requires sufficient contact pressure for leak tightness and lower undesirable residual stress in the transition region of the tube. The objective of this work is to assess various paths of roller for roll expansion of tube such that the residual tensile stress is reduced while maintaining the required leak tightness. Consequently, three dimensional, explicit finite element simulations, of the roll expansion process are carried out. Several roller paths are considered in the simulation to vary the strain path of deformation. Results showed that with increase in number of rotations of the roller, the residual stresses decreased. In addition, the contact pressure is found to be within acceptable range for leak tightness. But, beyond a certain number of rotations, the stresses are found to saturate, hence putting an upper bound to their number.
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