Investigation on Optimization of Finite Element Model for Stress Analysis of 12Cr1MoV Main Steam Pipeline Elbow

Stress analysis is of great significance for components in thermal power plants, and an inaccurate model could cause inaccuracy in the life assessment of the plant. During the manufacturing process of elbows, issues such as cross-sectional elliptical deformation and uneven wall thickness frequently occur. However, existing studies have not thoroughly investigated these phenomena. In this study, a modified finite element model based on the dimension of an actual elbow was established for stress analysis and compared with that of the ideal uniform model. Subsequently, microstructure characterization and mechanical property tests were conducted on the elbow to validate both models. The stress concentration area in the corrected model has shifted from the inner arc region of the ideal model to the inner wall of the neutral plane region. Both optical microscopy and SEM results indicate that microstructural degradation in the neutral plane region is more pronounced, characterized by non-uniform grains, coarse carbides, and creep cavities. The hardness values of the inner wall in the neutral plane area are significantly lower than that in the inner arc area, and the tensile sample in the neutral plane area fractures rapidly after yielding, exhibiting poorer toughness compared to the samples in the inner arc area. Moreover, the creep resistance in the neutral plane area is much lower than that in the inner arc area. By integrating finite element simulation with experimental validation, the accuracy of the corrected finite element model presented in this paper has been confirmed, providing valuable theoretical and experimental guidance for the life assessment of elbows in thermal power plants.