Publications

Abstract not provided.

The response of a variety of sucker rod couplings to an applied axial load was simulated using axisymmetric finite element models. The calculations investigated three sucker rod sizes and various combinations of the slimhole, Spiralock, and Flexbar modifications to the coupling. In addition, the effect of various make-ups (assembly tightness) on the performance of coupling was investigated. An axial load was applied to the sucker rod ranging from {minus}5 ksi to 40 ksi, encompassing three load cycles identified on a modified Goodman diagram as acceptable for indefinite service life of the sucker rods. The simulations of the various coupling geometries and make-ups were evaluated with respect to how well they accomplish the two primary objectives of preloading threaded couplings: (1) to lock the threaded coupling together so that it will not loosen and eventually uncouple, and (2) to improve the fatigue resistance of the threaded connection by reducing the stress amplitude in the coupling when subjected to cyclic loading. Perhaps the most significant finding in this study was the characterization of the coupling parameters which affect two stress measures. The mean hydrostatic stress, which determines the permissible effective alternating stress, is a function of the coupling make-up. Whereas, the alternating effective stress is a function of the relative stiffnesses of the pin and box sections of the coupling and, as long as the coupling does not separate, is unaffected by the amount of circumferential displacement applied during make-up. The results of this study suggest approaches for improving the fatigue resistance of sucker rod couplings.

3-D quasistatic finite element codes are being used at Sandia to simulate large room and pillar mines in rock salt. The two examples presented in this paper are of mines supported by US DOE, under the auspices of the Strategic Petroleum Reserve program. One of the mines is presently used as an oil storage facility. These simulations, validated by field measurements and observations, have provided valuable insight into the failure mechanisms of room and pillar mines in rock salt. The calculations provided the basis for further investigation and the ultimate decision to decommission the DOE oil storage facility.

A series of tests investigating dynamic pulse buckling of a cylindrical shell under axial impact is compared to several 2D and 3D finite element simulations of the event. The purpose of the work is to investigate the performance of various analysis codes and element types on a problem which is applicable to radioactive material transport packages, and ultimately to develop a benchmark problem to qualify finite element analysis codes for the transport package design industry. Four axial impact tests were performed on 4 in-diameter, 8 in-long, 304 L stainless steel cylinders with a 3/16 in wall thickness. The cylinders were struck by a 597 lb mass with an impact velocity ranging from 42.2 to 45.1 ft/sec. During the impact event, a buckle formed at each end of the cylinder, and one of the two buckles became unstable and collapsed. The instability occurred at the top of the cylinder in three tests and at the bottom in one test. Numerical simulations of the test were performed using the following codes and element types: PRONTO2D with axisymmetric four-node quadrilaterals; PRONTO3D with both four-node shells and eight-node hexahedrons; and ABAQUS/Explicit with axisymmetric two-node shells and four-node quadrilaterals, and 3D four-node shells and eight-node hexahedrons. All of the calculations are compared to the tests with respect to deformed shape and impact load history. As in the tests, the location of the instability is not consistent in all of the calculations. However, the calculations show good agreement with impact load measurements with the exception of an initial load spike which is proven to be the dynamic response of the load cell to the impact. Finally, the PRONIT02D calculation is compared to the tests with respect to strain and acceleration histories. Accelerometer data exhibited good qualitative agreement with the calculations. The strain comparisons show that measurements are very sensitive to gage placement.

A series of tests investigating dynamic pulse buckling of a cylindrical shell under axial impact is compared to several 2D and 3D finite element simulations of the event. The purpose of the work is to investigate the performance of various analysis codes and element types on a problem which is applicable to radioactive material transport packages, and ultimately to develop a benchmark problem to qualify finite element analysis codes for the transport package design industry. During the pulse buckling tests, a buckle formed at each end of the cylinder, and one of the two buckles became unstable and collapsed. Numerical simulations of the test were performed using PRONTO, a Sandia developed transient dynamics analysis code, and ABAQUS/Explicit with both shell and continuum elements. The calculations are compared to the tests with respect to deformed shape and impact load history.

A three dimensional (3D) finite element analysis of the Markel Mine located on Weeks Island was performed to: (1) evaluate the stability of the mine and (2) determine the effect of mine failure on the nearby Morton Salt mine and SPR facilities. The first part of the stability evaluation investigates the effect of pillar failure on mine stability. These simulations revealed that tensile stresses and dilatant damage develop in the overlying salt as a result of pillar loss. These tensile stresses extend to the salt/overburden interface only for the case where all 45 of the pillars are assumed to fail. Tensile stresses would likely cause microfracturing of the salt, resulting in a flow path for groundwater from the overlying aquifer to enter the mine. The dilatant damage bridges between the mine and the overburden in the case where 15 or more pillars are removed from the model. Dilatant damage is attributed to microfracturing or changes in the pore structure of the salt and could also result in a flow path for groundwater to enter the mine. The second part of the Markel Mine evaluation investigates the stability of the pillars with respect to three failure mechanisms: tensile failure, compressive failure, and creep rupture. A 3D slabbing pillar model of the Markel mine was developed to investigate progressive failure of the pillars and the effect of slabbing on mine stability. Based on a strain-limiting creep rupture criterion, pillar failure is predicted to be extensive at present. The associated loss of pillar strength should be equivalent to removing all pillars from the model as was done in the first part of this stability analysis, resulting in the possibility of ground water intrusion. Since creep rupture is not a well understood phenomenon, further development and validation of this criterion is recommended.

Three-dimensional finite element analyses of gas-filled storage caverns in domal salt were performed to investigate the effects of cavern spacing on surface subsidence, storage loss, and cavern stability. The finite element model used for this study models a seven cavern storage field with one center cavern and six hexagonally spaced surrounding caverns. Cavern spacing is described in terms of the P/D ratio which is the pillar thickness (the width between two caverns) divided by the cavern diameter. With the stratigraphy and cavern size held constant, simulations were performed for P/D ratios of 6.0, 3.0, 2.0, 1.0, and 0.5. Ten year simulations were performed modeling a constant 400 psi gas pressure applied to the cavern lining. The calculations were performed using JAC3D, a three dimensional finite element analysis code for nonlinear quasistatic solids. For the range of P/D ratios studied, cavern deformation and storage volume were relatively insensitive to P/D ratio, while subsidence volume increased with increasing P/D ratio. A stability criterion which describes stability in terms of a limiting creep strain was used to investigate cavern stability. The stability criterion indicated that through-pillar instability was possible for the cases of P/D = 0.5 and 1.0.

Finite element analyses of oil-filled caverns were performed to investigate the effects of cavern depth on surface subsidence and storage loss, a primary performance criteria of SPR caverns. The finite element model used for this study was axisymmetric, approximating an infinite array of caverns spaced at 750 ft. The stratigraphy and cavern size were held constant while the cavern depth was varied between 1500 ft and 3000 ft in 500 ft increments. Thirty year simulations, the design life of the typical SPR cavern, were performed with boundary conditions modeling the oil pressure head applied to the cavern lining. A depth dependent temperature gradient of 0.012{degrees}F/ft was also applied to the model. The calculations were performed using ABAQUS, a general purpose of finite element analysis code. The user-defined subroutine option in ABAQUS was used to enter an elastic secondary creep model which includes temperature dependence. The calculations demonstrated that surface subsidence and storage loss rates increase with increasing depth. At lower depths the difference between the lithostatic stress and the oil pressure is greater. Thus, the effective stresses are greater, resulting in higher creep rates. Furthermore, at greater depths the cavern temperatures are higher which also produce higher creep rates. Together, these factors result in faster closure of the cavern. At the end of the 30 year simulations, a 1500 ft-deep cavern exhibited 4 percent storage loss and 4 ft of subsidence while a 3000 ft-deep cavern exhibited 33 percent storage loss and 44 ft of subsidence. The calculations also demonstrated that surface subsidence is directly related to the amount of storage loss. Deeper caverns exhibit more subsidence because the caverns exhibit more storage loss. However, for a given amount of storage loss, nearly the same magnitude of surface subsidence was exhibited, independent of cavern depth.

Structural calculations were performed to evaluate the source-term nuclear fuels transport cask (ST Cask) under various hypothetical accident scenarios. (1) Three-dimensional transient dynamic analyses were performed to evaluate the strength of the cask`s end-closure clamp mechanism. The calculations were performed for two impact orientations: a side impact and a 20{degrees} corner impact. The calculations identified three weaknesses in the clamp design: a gap designed between the clamp and the cask provides a deformation mode which loosens the clamp, two unconstrained swing bolts used to fasten the clamp can lose preload and come free; and insufficient stiffness of the clamp in torsion. (2) An axisymmetric finite element model was used to evaluate the dynamics of end-drops from 5 and 10 ft. The calculations show that loads generated in the end-drops could break the payload support cable and damage the payload winch. Lead slump resulted in both end-drop calculations. The stresses generated in the cask wall during the end-drops was insufficient to cause buckling. (3) To determine the factor of safety to yield, calculations in which the cask was treated as a beam loaded under its own weight were performed for two support configurations: simply supported at both ends and simply supported at the center (trunnion loading). (4) The survival of the cask from a 1-m drop onto a mild steel punch was evaluated based on equations derived from empirical data. The calculations showed that the ST Cask could survive such an event. (5) Finally, the bolt configuration for the upper-closure was analyzed and determined to be inadequate because it does not prevent the closure from sliding relative to the cask body. Specific recommendations for design changes are made in the report to eliminate identified problems.

Coupled thermal-structural finite element calculations of a reflux pool-boiler solar receiver were performed to characterize the operating stresses and to address issues affecting the service life of the receiver. Analyses performed using shell elements provided information for receiver material selection and design optimization. Calculations based on linear elastic fracture mechanics principles were performed using continuum elements to assess the vulnerability of a seam-weld to fatigue crack growth. All calculations were performed using ABAQUS, a general purpose finite element code, and elements specifically formulated for coupled thermal-structural analysis. Two materials were evaluated: 316L SS and Haynes 230 alloys. The receiver response was simulated for a combination of structural and thermal loads that represent the startup and operating conditions of the receiver. For both materials, maximum stresses in the receiver developed shortly after startup due to uneven temperature distribution across the receiver surface. The largest effective stress was near yield in the 316L SS receiver and below 39 percent of yield in the Haynes 230 receiver. The calculations demonstrated that stress reductions of over 25 percent could be obtained by reducing the aft dome thickness to one closer to the absorber. The fatigue calculations demonstrated that the stress distribution near the seam-weld notch depends primarily on the structural load created by internal pressurization of the receiver rather than the thermal, indicating that the thermal loads can be neglected when assessing the stress intensity near the seam-weld notch. The stress intensity factor, computed using the J-integral method and crack opening-displacement field equations, was significantly below the fatigue threshold for most steels. The calculations indicated that the weld notch was always loaded in compression, a condition which is not conducive to fatigue crack growth. 15 refs., 30 figs., 3 tabs.

A dynamic finite element analysis was performed to study the penetration mechanics of a commercial fastener called Metal-Tack{reg sign}. This study evaluated the fastener and identified parametric changes required for attachment to AISI 1070 steel (R{sub c} = 26), a material harder than the fastener was designed for. A set of baseline calculations was performed to evaluate the fastener's performance in yellow brass, a much softer material. The analysis indicated that a driving energy of 3.03 ft{center dot}lbs was required to drive the tack into yellow brass. Excellent correlation of this model with experimental data provided confidence for applying the model to AISI 1070 steel. Tack performance was investigated with respect to variations in driving energy and tack strength. The results demonstrated that increasing driving energy was not sufficient for a successful attachment in the steel. An increase in tack strength was also required. Higher tack strength was obtained by increasing the heat treat specification of the tack material, Carpenter R.D.S. steel, to obtain a hardness of R{sub c} = 60. With this increase in strength and a driving energy of 20.8 ft{center dot}lb, the results indicated that the tack would attach but develop high plastic strain (21.5%) during attachment. The calculations were confirmed with tests using a high energy pyrotechnic driver developed to attach the tack. Finally, a geometry modification intended to reduce stress concentrations in the tack was evaluated experimentally but not computationally. The experimental results indicated an improvement in the tack strength and attachment quality. 4 refs., 19 figs., 4 tabs.