Finite element evaluation of clearance effect on tube-to-tubesheet joint strength

Tube-to-tubesheet joint strength is measured in terms of residual contact pressure between the tube's outer surface and the tubesheet hole surfaces. The joint integrity is affected by several design parameters, including the type of material and the initial radial clearance.The present work complements an experimental program on the effect of over-tolerance on heat exchanger tube-to-tubesheet joint strength. Finite element analyses address the effect of initial clearance on contact pressure and percent tube wall reduction. Results show that for low strain hardening materials the initial clearance effect is negligible. However, higher levels of strain hardening have a significant effect on residual stress and percent wall reduction. For low clearances, the calculated residual contact pressure compares well with an analytical result and with that inferred from the experimentally measured pull out force. The variation of the percent wall reduction with initial clearance is found to be similar to that measured.