A methodology for on-line calculation of temperature and thermal stress under non-linear boundary conditions

Abstract In the literature many works have been written dealing with the task of on-line calculation of temperature and thermal stress for machine components and structures, in order to evaluate fatigue damage accumulation and estimate residual life. One of the most widespread methodologies is the Green's function technique (GFT), by which machine parameters such as fluid temperatures, pressures and flow rates are converted into metal temperature transients and thermal stresses. However, since the GFT is based upon the linear superposition principle, it cannot be directly used in the case of varying heat transfer coefficients. In the present work, a different methodology is proposed, based upon CMS for temperature transient calculation and upon the GFT for the related thermal stress evaluation. This new approach allows variable heat transfer coefficients to be accounted for. The methodology is applied for two different case studies, taken from the literature: a thick pipe and a nozzle connected to a spherical head, both subjected to multiple convective boundary conditions.