Stress concentration factors for pressurized elliptic crossbores in blocks

Intersecting bore geometries are used in a number of industrial applications including heavy-walled pressure vessels containing oil holes for lubrication, ports for valves and fluid ends of reciprocating pumps. The bore intersection location is a stress concentration point where the maximum hoop stress can be many times the fluid pressure in the bores. Intersecting circular holes in heavy-walled cylinders and rectangular blocks have been extensively investigated. Specifically, stress/pressure concentration curves for intersecting circular bores in rectangular blocks were presented by Sorem et al. [Sorem JR, Shadley JR, Tipton SM. Design curves for maximum stresses in blocks containing pressurized bore intersections. ASME J Mech Des 1990; 113: 427–31.]. However, stress/pressure concentrations due to intersecting elliptic bores have not been broadly investigated. With the availability of computer numerical control (CNC) machinery, bores with elliptic crosssection can be produced with relative ease. In this paper, hoop stress concentration ratios are developed for elliptic crossbores in rectangular blocks. Results indicate that introducing elliptic crossbores, rather than circular ones, significantly reduces the hoop stress concentration factor at the crossbore intersection. Also, the presence of intersecting crossbores has a major effect on the fatigue life of pressure vessels [Badr EA, Sorem JR, Jr Tipton SM. Evaluation of the autofrettage effect on fatigue lives of steel blocks with crossbores using a statistical and a strain-based method. ASTM J Test Eval 2000; 28: 181–8.] and the reduction of hoop stress concentration is expected to enhance the fatigue life of pressure vessels containing crossbores.