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The conventional elastic analysis of thick walled cylinders to final radial & hoop stresses is applicable for the internal pressures up to yield strength of material. The stress is directly proportional to strain up to yield point Beyond elastic point, particularly in thick walled cylinders. The operating pressures are reduced or the material properties are strengthened. There is no such existing theory for the stress distributions around radial holes under impact of varying internal pressure. Present work puts thrust on this area and relation between pressure and stress distribution is plotted graphically based on observations. Here focus is on pure mechanical analysis & hence thermal, effects are not considered. The thick walled cylinders with a radial cross-hole ANSYS Macro program employed to evaluate the fatigue life of vessel. Stresses that remain in material even after removing applied loads are known as residual stresses. These stresses occur only when material begins to yield plastically. Residual stresses can be present in any mechanical structure because of many causes. Residual stresses may be due to the technological process used to make the component. Manufacturing processes lead to plastic deformation.

The following are the principal objectives of the work.

Stress analysis of thick walled cylinders with radial holes & understand the effect of relative dimensions/parameters of hole on equivalent stress developed due to internal pressure.

Study of Auto frottage process & find out the residual stresses theoretically & using FEM Method by considering bi-linear kinematic hardening state (elasto-plastic state), for uniform cylinder as well as cylinder with radial hole.

Depicting relationship between internal pressure applied and equivalent stress graphically for elastic-plastic cases of uniform cylinder as well as cylinder with radial holes.