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The catastrophic failures of these thick-wall cylinders are mainly due to the presence of inherent cracks in the material. The present study aims to deal with the analysis of stress for a given range of inside pressure. The paper deals with the calculation of radial and tangential stresses for various external pressure-to-internal pressure ratios and external radius to internal radius of the thick-walled cylinder.

The inlet line to the combustion chamber normally has an internal diameter of 150 mm and has a thickness of 25 mm. Normal temperature of the working fluid is about 80°C and the outside temperature is kept as room temperature. The present work deals with the stress analysis of the inlet line with and without internal crack. Also the stress intensity factors are calculated to check with the fracture toughness. Analysis is done both theoretically and by FEM by using the well-known software ANSYS.

Results show that the radial stress is independent of the external radius-to-internal radius ratio, while the tangential stress increases.

In process industries like nuclear or chemical, etc., structures in the form of thick-walled cylinders play a vital role, as its failure can affect humans and the environment. Because of this, the design and analysis of the above cylinders are of much significance.

Due to constant or cyclic operating pressure of pressure vessels and its corresponding pipelines usually in the form of thick-walled cylinders, reliability of the materials and structures used is of critical importance, as its failure can be deadly and possess lethal dangers when the cylinder contains flammable, toxic or reactive working fluid. The major ruling factors for the failure are none other than stress-related defects and presence of cracks.