In this paper, an optimization method for a tee is proposed. A finite element model of a tee is built and its reliability is demonstrated by experiment. Analysis models with different fillet radii are analyzed. The results show that changing the fillet radius can not distinctly change the stress intensity level. Therefore, deformation relaxation, a new method for lowering stress intensity levels, is proposed. The method’s core is that the original shape of the tee is modified by deformation displacement. The computed results show that the decrease of the highest stress intensity is approximately in proportion to the modification. When the maximum modification is up to 10% of the outer diameter of main pipe, the highest stress intensity decreases by 52.2%.

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