Report 1763 = HYDROSTATIC TESTS OF STRUCTURAL MODELS FOR HYDROMECHANICS = =: = PRELIMINARY DESIGN OF A WEB-STIFFENED SANDWICH PRESSURE HULL (e) AERODYNAMICS Kenneth Hom and William F. Blumenberg Oo STRUCTURAL MECHANICS O STRUCTURAL MECHANICS LABORATORY jie RESEARCH AND DEVELOPMENT REPORT 1 ape — fe us ue September 1963 )% fe Report 1763 | 0 18 HYDROSTATIC TESTS OF STRUCTURAL MODELS FOR PRELIMINARY DESIGN OF A WEB-STIFFENED SANDWICH PRESSURE HULL by Kenneth Hom and William F. Blumenberg September 1963 Report 1763 S-F013 03 02 S-FOT3 91 03 TABLE OF CONTENTS IMIOIDIEIG OWSG coocns00000 0000 00000000000 IMCOIDITIs OWS cocboocosccoc00dg000000000 INSTRUMENTATION AND TEST PROCEDURE WITS RUSSO ILA ANID) IDIEXGIWISISUMOIN) 56660055506 MODELS OV-1 AND OV-Z ............... MODELS OV-3, OV-4, AND OV-5........ IONE IDURD TE /NICOIN (QD RUBS WIGS 6550655500600 AXISYMMETRIC MODE OF COLLAPSE ... eee ee oe eo eo ew oe ee ee ee eo 2 © © © © © © 8 © © © 8 ew ew ee 8 © 0 © © © © © © © © ew ee ee ee 8 ee © © © © © © © © © ew 8 ee ee 2° © © © © © © © © © © 8 ee ee ew 8 © © e@ © © © © © © ee ew 8 8 8 ee 8 ee © © © © © © © © © © 8 ew ew ew 8 GENERAL-INSTABILITY MODE OF COLLAPSE .............. COINGILUSIOINS ¢co0¢000 00d 0b050b0005000000000 ANGISIN(O Wh IGIDIDYGIMUDINIES) 5 50065000000000000000 IRIEIP IDIRUDINGGITS pg oooo cop o 0 co Dood 000000000000 li © © © © © © © © © © © © © © 8 ew ew 8 © © © © © © © © © © © © ee 8 8 8 8 ee © © © © © © © © © © © © 8 8 8 Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 11 12 16 17 LIST OF FIGURES Page Inboard Profile of Proposed Oceanographic Vehicle .... 3 Sandwich Cross Sections Showing Prototype Dimensions) ot Modelisimiested ee cic -ieneielen ences 4 Details @# MO@cdelOWSl soscccoctoobco00v00000000u0000 6 Details of Models OV-3 and OV-4 ............2.00200- 8 Model OV-4 Prior to Assembly ..............220-200- 9 Assembly Drawing of Model OV-3..............+-.---- 9 Theoretical Stress Intensity in Critical Shell Regions fOr LoS Warree IDSSiesns ISKVOSEYTEVECC, 5 005600000000000400 11 Details © MI@Eel OWA socascoscedcsasnc00000000000000 12 Die taullisue faNlodielJON— Sic. acuek. «rue hs cea © haa ee 14 Theoretical and Measured Strain Sensitivities FORMIVIG Cele ONWa lh Bes AE BR SP SS AOU Sat cieeh atte che retrace: anor ememeete 15 Theoretical and Measured Strain Sensitivities LO TMINTO CE VKO) Wisi 0 eres erste oy ior kno ac ae eee ee ate eto a ae nhier Shoe e eee me 16 View of Axisymmetric Crease in Outer Shell Git IMIO@GIEN OWS soococaccdccsogocn0a0 oo OGD DOO DODO DONE 18 View of Overall Failure of Model OV-2............... 18 Strain Plots of Gages Located at Station 103 Om, MI@cell OW gooconoccodcacnng0d00DageNsDDOa DO OOON 19) Strain Plots of Gages Located at Station 113 Gin MICGIEl OW! peoocaccns0gadc00c0000005 000008 *Pushetictents 20 IMi@Glell OW =3 antier Collllajos@ cocasoooonc000cc000000000K00 22 iMicglell OWa4 ante COMADSS soo0cn500000s0000000000006 23 iii LIST OF FIGURES (continued) Page igure 18s. Mod ell@NVi—SratternsGolllapsiene yarn clei tel eue reine aie nei 24 Figure 19 - Stress-Strain Curve of Specimen Taken from 77lnch-— Thick HY 80)Steeljelatem ner. yn ae ee 26 Figure 20 - Typical Stress-Strain Curve of Compression Specimen Taken from Nascent Titanium Alloy Bar Used in Model's: OV —3xamdiOWi~ 4a neyo cick yeteA. uc! — 16621 16.084 INCH DIAMETE 13.105 INCH es =| eat WELDS | INCH LONG ON 1.99 !1NCH CENTERS STAGGERED IN ADJACENT FRAMES DETAIL OF TYPICAL SANDWICH SECTION sagas 1.009 === tated All dimensions are in inches, DETAIL OF END SANDWICH SECTION Figure 3 — Details of Model OV-1 psi were estimated for the original flat plating and as close as possible to the regions of failure observed on the inner and outer shells of the model, respectively. The webs of the sandwich section were made of three equal segments cut from the flat plating and butt-welded together to form complete cir- cular rings. After the inner shell was rolled and welded, each web was positioned and welded continuously to the inner shell. The outer shell was slotted, rolled into a cylindrical form, and placed outside the web-and- inner shell assembly. The outer shell was then plug-welded to the webs at those points where the slots were cut. The model was designed using an end arrangement to preclude pre- mature failure near the rigid closure bulkheads; see Figure 3. It was made pressure-tight by welding heavy rings on each end and then attach- ing a heavy closure bulkhead to each ring. MODELS OV-3 AND OV-4 The next step in the sequence of developing background information before going to some large-scale fabricated titanium models was to test some small-scale machined titanium models which could be made imme- diately at a very nominal cost. For this reason, Models OV-3 and OV-4, representing one-diameter and four-diameter lengths, respectively, of the original design, were built and tested. The dimensions and design details of Models OV-3 and OV-4 are shown in Figure 4. Dimensional tolerances between the outer shell and the webs were specified so that a maximum clearance of 0.0008 in. be- tween these two elements would exist when the outer shell was slipped over the inner shell-web combination. Figure 5 shows the component parts of Model OV-4, prior to assembly. After each model was assembled, the ends of the cylinders were ground flush to ensure proper distribution of the axial pressure load to the inner and outer shells. The models were designed using an end arrange- ment, as shown in Figure 4, to preclude premature failure near the rigid closure rings. They were made pressure-tight by using a heavy plate and an 'O''-ring seal at each end. The closure plates were not physically at- tached to the cylinder but were seated in place by the pressure. Figure 6 is an assembly drawing of Model OV-3. Models OV-3 and OV-4 were machined from a 22-in.-diameter bar of 6Al1-4V a-titanium alloy. Sixteen compression specimens were taken from the bar; the yield strength, based on a 0.2-percent offset, ranged from a low of 126, 000 psi to a high of 145, 000 psi with an average value of about 138,000 psi. Since the yield strength and stress-strain curve for titanium alloys are sensitive to the rate of loading,* these specimens were tested at a rate corresponding to the pressure loading of the models. The rate of loading was equivalent to a stress-intensity level of 550 psi/min, 2.600 OV-3 2.632 OV-4 8.888 9 FRAME SPACES AT 0.184=1656 OV-3 43 FRAME SPACES AT 0.184=7.912 OV-4 0.146 “soso Fe 0.0300+0002 | meson al 0.0300+ 0002 + 0.0000 ~ 0.0004 ae 1.9339 came Ct a —. INNER SHELL Ov-3 2.632 OV-4 8.888 Wain _f ey OUTER SHELL ALL DIMENSIONS ARE IN INCHES Figure 4 - Details of Models OV-3 and OV -4 NM ~ ~ ~ tJ aed a no a Figure 5 —- Model OV-4 Prior to Assembly “N 9 Bio SB; hw Jy § 7} y Dav. 2S eee, mz (HY YI it OUTER SHELL ne LJ = - O-RING SEAL CLOSURE ONE INCH BULKHEAD Figure 6 — Assembly Drawing of Model OV -3 computed on the basis of the Hencky-Von Mises criterion for a monolithic thick cylinder of equivalent weight. The one-diameter-long model (OV-3) was tested to determine wheth- er an increase in strength for a titanium hull similar to that observed for the steel model, OV-1, could be realized as a consequence of the effects of strain hardening. In addition, it was felt that this test of Model OV-3 would provide information on the feasibility of constructing models by slip- ping one shell over the other, and also would indicate whether this novel technique involved a loss of structural strength, if any existed, compared to the method utilized for Model OV-1, where the outer shell of the sand- wich section was physically joined to the webs by slot welding. The four-diameter-long model (OV-4) was intended to determine the collapse pressure and mode of failure for the overall cylindrical compart- ment of the original design. This model was considered necessary since the general-instability strength could not be determined by testing short- length cylinders such as Models OV-1 and OV-3. MODEL OV-2 By the use of the elastic analysis of Reference 3, it was possible to predict high bending stresses in both shells between adjacent webs of the original sandwich design; in addition, the webs were found to be under- stressed. These results indicated that an improved design could be ob- tained, without increasing the weight of the structure, by a redistribution of the material. Several improved designs were analyzed. One of these: designs is shown in Figure 2b and is represented by Model OV-2. Calcu- lations indicated that the OV-2 configuration represented a more balanced design than that originally proposed. Thatis, the spread between the max- imum and the minimum shell stresses is reduced in an attempt to more uniformly stress the entire sandwich cross section. It should be noted, however, that a ''balanced stress design'' need not represent the optimum structure for a given weight when the instability modes of failure are also of significance, as in the present design ofalonghullcompartment. Figure 7 presents a comparison of the computed stresses in the critical regions of a typical sandwich section for each of the three designs investigated. 10 OUTER SHELL WINNER SHELL OUTER SHELL INNER SHELL OUTER SHELL INNER SHELL MODELS OV-I, OV- 3, AND Ov-4 (ORIGINAL DESIGN) MODEL OV-2 (BALANCED STRESS DESIGN) Stress values were computed from Sees sis of Reference 3, with an umed value of 0.33 as Poisson’s “55 x Eee and a © elven in pal per psi of Tr ‘ Tr , den ea eee shown in this 2 “ figure represent the circumferential and longitudinal shell stresses and are written vertically and horizon- Figure 7b tally, respectively. MODEL OV-5 (SUGGESTED REDESIGN) Figure 7c Figure 7 — Theoretical Stress Intensity in Critical Shell Regions for the Three Designs Investigated te a c wu Ww a ao 17.653 = z 3 a a zz lo} Led fo} Mm eq © SLOT WELDS | IN. LONG ON 1.978 IN. CENTERS ees STAGGERED IN ADJACENT FRAMES a 0.239 0.296 DETAIL OF END SANDWICH SECTION All dimensions are in inches. Figure 8 — Details of Model OV-2 The primary purpose of Model OV-2 was to determine whether an increase in interbay strength exists over that of the original design and to verify the elastic behavior predicted by the analysis of Reference 3. It was felt that these objectives could be accomplished by fabricating a model from steel plating of only about one diameter in length. Thus, Model OV -2 affords a direct strength comparison with Model OV-1. The dimensions and design details of Model OV-2 are shown in Figure 8. Fabrication procedures for this model were identical to those for Model OV-1. The inner shell had an average thickness of 0.296 in. 12 and a yield strength ranging from 104, 000 psi to 108,000 psi. The outer shell had an average thickness of 0.259 in. and a yield strength ranging from 109,000 psi to 113,000 psi. Yield strength values of 104, 000 psi and 109, 000 psi were estimated for the original flat plates and as close as possible to the regions of failure observed in the inner and outer shells of the model, respectively. MODEL OV-5 From the tests of the titanium models, OV-3 and OV-4, it was con- clusively determined that inelastic general instability is the critical mode of failure for the original design. Both of these models had the same typi- cal interbay configuration. The only difference was in the overall length; OV-3 was one diameter long, whereas OV-4 was four diameters long. As a consequence of its shorter length, Model OV-3 had an elastic general- instability pressure twice that of the longer model. The observed collapse pressures of these two models reflected this difference. When extrap- olated to the specified yield strength of 120,000 psi, the shorter model (OV-3) failed at a pressure 10 percent above the minimum specified col- lapse pressure and the longer model (OV-4) failed 3.5 percent below this value. It appeared that a redesign of the basic sandwich configuration to increase the general-instability strength was necessary to ensure that the fabricated structure would meet the minimum design pressure. One redesign possibility would be to increase the depth of the webs at the ex- pense of making them thinner so as to retain the same overall weight of hull structure. Another possible redesign would be to decrease the over- all stress intensity through the sandwich cross section by adding additional material to the two cylindrical shells. Either of these two alternatives, or a combination of them, may be necessary to attain the stated objective. A small-scale, four-diameter-long, machined model (OV-5) incor- porating the first alternative was designed and constructed. The overall depth of the sandwich cross section in this design corresponds to 12.9 in. as compared with 10 in. in the original design (see Figure 2); the web thickness was reduced to 12 in. in order to retain, as closely as possible, 13 ———_- 15.448 ! 43 FRAME SPACES AT 0.3208 13.760 0.160 ers : + 0.0002 0.43 0.0520 £0.0002 7 15.448 3.950 OUTER SHELL All dimensions are in inches. Figure 9 - Details of Model OV-5 the original hull weight. The elastic general-instability strength for the four-diameter-long redesigned model (OV-5) is exactly the same as that for the one-diameter-long model (OV-3) based on the original design. The dimensions and design details of Model OV-5 are shown in Fig- ure 9. Construction of this model was similar to that of Models OV-3 and OV-4. It was machined from a 44-in.-diameter bar of 6Al1-4V a-titanium alloy. Six compression specimens were taken from the bar; the yield 14 strength, based on a 0.2-percent offset, ranged from a low of 121,000 psi to a high of 132,300 psi with an average value of about 127,500 psi. The specimens and model were loaded at twice the rate used for Models OV -3 and OV-4. INSTRUMENTATION AND TEST PROCEDURE To study the elastic and inelastic behavior of the structure and to facilitate interpretation of the mode of failure and collapse pressure, strains were measured on Models OV-1 and OV-2 by electrical resistance strain gages. Strain-gage locations for Models OV-1 and OV-2 are shown in Figures 10 and 11, respectively, together with the measured strain sen- sitivities. Because of the small size of Models OV-3, OV-4, and OV-5, it was not feasible to take strain measurements on these models. ° nu J o o 5 i VY S a oJ aq iS g se m ° to} =) J ° ' -0.51 -0.43 5-0.01 5 2 gobs m4 -0.41 -0.40 OUTSIDE i 1 Ub ee 1 1 GENERATOR “an INSIDE T T iT TI 010 0.17 1ap3-023 (Xe :14) Abe -opi 3 = 08 B eo 2 BY 6 bf 1 @ wt ? 3 ' t U ® 1 1 2 3 4 5 6 v 8 9 10 WW 12 13 14 WEB NUMBERS o Nn a 8 © OG & -0.05-041 +0.02 OUTSIDE fy dt GENERATOR “3” INSIDE ops aah als MEASURED STRAINS SON Oe8 23, ao ao o ee a Sis o Le nu Nu ° ° ' 1 +0,08 - 0.32 GENERATOR ‘A" ft Jt Strain sensitivities are given in = OUTER microinches per inch per psi of ick g pressure. GENERATOR "B" INNER T SHELL -0.01 -027 BR o mS SLOT WELDING IN o °8 « Fa OUTER SHELL : ' uw THEORETICAL STRAINS Figure 10 - Theoretical and Measured Strain Sensitivities for Model OV-1 15 a & ra 2 O42 8 ~ 3 o.8 oO 5 fo} < °o ” fo] ¢ o 1 ° Tee Ori 0 3 > on GC oF -0.27 our -ais | -0.17 ' -O13 '-0.27 OUTSIDE Ju Jt Haat | (laure! Sal baer GENERATOR th INSIDE Ms T Tie eel T T -0.12 - - o- = = Dt ays 0.8 0.17 0.16 0.14 3 3 Be @ n a 1 ! ay ° v liar 3 4 5 6 7 8 9 10 " 12 13 4 15 16 17 WEB NUMBERS Q - b Q g J 3 Bie Co) So o -0.15 ouT 7 -O.12 OuT OUTSIDE 1 db 1 GENERATOR "A" INSIDE T Toot T -als -al7 -0.18 -0.15 8 BB by 3 o oOo 9° fo 1 } ' ' ! o nt u 8 OG T are functions of geometry and are given by Equations Wale The inelastic general-instability pressures p, for the titanium models were determined as follows: Values of E, and E; were deter - mined as a function of o; by using the stress-strain curves obtained from the uniaxial compression tests. Then p, was plotted as a function of o; using Equation [1]. Similarly, the applied pressure p was plotted against o; using Equation [3]. The inelastic general-instability pressure for each model was then obtained from the intersection of the two curves of p, versus o;, and p versus 9;, as shown in Figure 21 for Model OV-4. The i inelastic general-instability pressures thus obtained are listed in Table 2; 31 they compare very favorably with the respective experimental collapse pressures. It is recalled that examination of Models OV-3 and OV-5 after col- lapse (see Figures 16 and 18) revealed extensive corrugation of the inner and outer shells between adjacent webs, indicative of gross yielding of the shell elements. Also, the observed collapse pressures were in excel- lent agreement with the computed values p,; see Table 2. Since the in- elastic general-instability pressures are also in good agreement with the experimental collapse pressures, it appears logical to conclude that pos- sibly the short one-diameter model (OV-3) of the original design and the four-diameter model (OV-5) of the suggested redesign may be of sucha balanced nature that in each case the two modes of axisymmetric plastic collapse and inelastic general instability occurred simultaneously. The aforementioned procedure for determining the inelastic general- instability pressure p, for a web-stiffened sandwich cylinder may appear to be somewhat empirical. However, it does define the important feature of the dependence of the inelastic general-instability strength on the stress- strain characteristics of the material, and also affords a means for ob- taining a good estimate of strength for this mode of collapse. Moreover, Models OV-3, OV-4, and OV-5 were machined from nascent bars of tita- nium alloy so that no appreciable residual stresses existed in these small- scale models, as would occur in a fabricated structure due to rolling and welding of flat plating. Such built-in stresses would effectively alter the shape of the stress-strain curve so that collapse strength of a fabricated sandwich hull may be considerably lower than that observed from tests of initially stress-free models. The question of how much strength reduction would occur can only be answered by testing some large-scale fabricated models in which the influences of residual stresses and out-of-roundness are present. If the observed collapse pressure of 11,100 psi for Model OV-4 is extrapolated to a yield strength of 120,000 psi, a pressure of 9650 psi is obtained. This value is 3.5 percent below the minimum design collapse pressure of 10,000 psi. Since the mode of failure observed for Model OV-4 appears to be greatly influenced by the shape of the stress-strain curve of the material, the collapse pressure of the fabricated prototype 32 hull could be even lower. On the basis of these results it can be concluded that the original design would prove inadequate in meeting the minimum specified collapse pressure of 10,000 psi. When the observed collapse pressure of Model OV-5, incorporating the suggested redesign in a long cylinder length, is extrapolated to a yield strength of 120,000 psi, a pressure of 11,290 psi is obtained. This is 13 percent above the minimum specified. The question as to whether this represents an adequate margin for the fabricated hull remains unanswered at the present. In addition, the question of fatigue strength for the sand- wich hull may be of some concern since stresses on the order of 90 per- cent of the minimum specified yield strength (120, 000 psi) at an operating depth of 15,000 ft are indicated by the analysis of Reference 3. Before any final conclusions can be drawn concerning the adequacy of the suggested redesign, it will be necessary to test larger scale tita- nium models which are fabricated to be identical in all respects, except size, to those anticipated in the prototype. This should be done so that all factors which appear to influence static and fatigue strength are adequately considered. At this stage of the preliminary design studies, it can only be said that the OV-5 redesign may represent a possible hull structure for the proposed oceanographic vehicle. CONCLUSIONS 1. The test results obtained with the one-diameter-long model (OV -3) indicate that the interbay strength of the original sandwich hull design exceeds the desired collapse pressure of 10,000 psi. Also, the construction technique of slipping the outer shell over the integral web- and-inner-shell assembly, without physically joining the webs to the outer shell, does not appear to prejudice structural strength. The test results obtained with the four-diameter-long model (OV-4) indicate that the crit- ical mode of failure is one of inelastic general instability and that the original design is not adequate to satisfy the minimum specified collapse pressure. 33 2. Tests of a machined model (OV-5), incorporating a redesign of the sandwich configuration, resulted in a collapse strength 13 percent higher than the minimum specified. The critical mode of failure for the redesign is the same as that for the original design. It is a mode which is greatly influenced by the shape of the stress-strain curve of the mate- rial in the structure. 3. Before any final conclusions can be drawn concerning the ade- quacy of the suggested redesign, it will be necessary to test larger scale fabricated models with built-in residual stresses and out-of-roundness to simulate the effects due to rolling and welding of plating as expected in the fabrication of the prototype. ACKNOWLEDGMENTS The authors are indebted to Mr. William E. Ball, Jr., who, prior to leaving the Model Basin, served as project manager of this program. He conducted the pertinent strength calculations and worked out the neces- sary details for the construction and instrumentation of Models OV-1 and OV-2. They are also indebted to Mr. John G. Pulos for his suggestions and advice. 34 REFERENCES 1. Bureau of Ships ltr S-F013 03 02 Ser 442-219 of 16 Jan 1962 to David Taylor Model Basin. 2. Blumenberg, W.F., etal., 'Investigation of the Strength- Weight Characteristics of Cylindrical, Sandwich-Type Pressure Hull Structures," David Taylor Model Basin Report 1678 (in preparation). 3. Pulos, J.G., ''Axisymmetric Elastic Deformations and Stresses in a Web-Stiffened Sandwich Cylinder under External Hydrostatic Pressure, "' David Taylor Model Basin Report 1543 (Nov 1961). 4. Willner, A.R. and Sullivan, V.E., ''Progress Report —- Metallurgical Investigation of Titanium Alloys for Application to Deep- Diving Submarines, '' David Taylor Model Basin Report 1482 (Dec 1960). 5. Bryant, A.R., "Hydrostatic Pressure Buckling of a Ring-Stiffened Tube, '' Naval Construction Research Establishment Report NCRE/R 306 (1954). 6. Krenzke, M.A. and Kiernan, T.J., "Structural Development of a 15,000- to 20,000-Foot Titanium Oceanographic Vehicle, '' David Taylor Model Basin Report (in preparation). 35 levee oh (uh: i wen bth ee ait ah dike ooelyt cfd is PenoRey” ienwighkn bisa hi ghey aa an AveP ab pire sigee Yuet s6! ee, ah aa “ aie} pi shat ee aur vi RHLTe: yet ek Pe hes a the, ‘Wha nat at tb Saale = si: it bes Bk 3 ity Eee ais oe twit alate ogy, toby bine a Pa ., Patnce' 4 / ee aes rat: \i he pagent: ap hares ied oh hg pla ana et wory boy ht pa ROL ta¢ va viii at F rs gh ehh aie 608 po tric aed fe ewan ido fel Wh Ph ihe! Whe Nish poh Bike elk att hdutal a pro) aint Be Patt ebyaakest fad Teh: shunt evant ees ag hi) 20) jagraae ened Javioas Ment iy davy ce Ray Ph Oat tal eA MOLY eA ab ae yeh, bv) Ohio bid Ce bg is Bu he : itt ae pen rhe mw faa ede NA i art LN high. 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