The aim of this paper is to investigate the effect of angular rotational misalignment in pipe structure on the deflection based convolution stresses. Such stresses are generated in the thin walled unreinforced bellows compensators during the expansion-contraction function. On the convolution geometry, the most vulnerable stress type is meridional deflection stresses under the internal pressure. Therefore, it’s critical to check the structural integrity of pipe systems with bellows expansion joints, which typically connected to the process equipment’s including boilers, pressure vessels, reactors, heat exchangers, refineries, and so on. The findings of theoretical and experimental investigations of thin-walled unreinforced conditioned bellows subjected to different angular rotations are presented in this paper. The meridional deflection stresses are investigated for the different operating pressures when bellows subjected to angular rotations of 1°, 1.5° and 2° in the flexural plane. In addition, the testing is performed along various longitudinal lines across the periphery of the bellows to determine the maximum induced stress points on the convolution profile. The higher meridional stress is seen to be the bending stress at the bottom curved toroidal section of the convolution, which approaches towards the elastoplastic regime at 1° to 2° of angular deviation in flexural plane. These extreme stress points may prove the risky areas at the root of the convolution for the fatigue failures. Further, the results of the maximal convolution stress assessment are useful in predicting the structural integrity of bellows in elastic regime, when prone to the angular shift.

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