Finite element analysis of deformation and fracture of an exploded gas cylinder

This paper presents the finite element simulations of deformation and fracture of a gas cylinder which catastrophically failed as a result of an accidental explosion. The results of a previous detailed investigation of this incident indicated that detonation of a low-pressure oxygen-rich mixture of hydrogen and oxygen was the cause of the cylinder failure. In the current study, the finite element method was used to provide a more realistic modeling of geometry, material behavior, and boundary conditions of the cylinder. The overall transient dynamic response of the cylinder to gaseous detonation loading was studied using the ANSYS/LS-DYNA V10 package and the crack growth simulations were performed using the WARP3D-R15 research code. The crack growth analyses were performed using interface cohesive elements. The finite element results were validated using analytical solutions and data collected from the remains of the cylinder. The simulations clearly showed that the stresses caused by the assumed loading profile were indeed capable of creating local ruptures at the actual crack initiation sites. It was also shown that the self-similar growth of the initial axial crack in the main body of the cylinder was a fatigue-type incremental growth governed by the structural waves. The subsequent cyclic bulging of the crack flaps and the resultant crack curving and branching were also simulated.