| Residual Stress Distribution in Large Tonnage Tempered
Glass Insulators: A Numerical and Experimental Study |
Sirui Chen, Chengyou Wei, Liming Wang and Bin Cao
Pages : 24-32
DOI: 10.1080/0371750X.2026.2619522 |
| Abstract |
| Glass insulators are critical components in overhead transmission lines, and their
reliability is closely tied to residual stress introduced during tempering. Due to their
non-uniform geometry, understanding the surface stress distribution is essential for
explaining self-explosion failures. This paper presents a coupled CFD-FEA numerical
framework to simulate residual stress in large-tonnage tempered glass insulators.
CFD is first used to model fluid and temperature fields during tempering. These results
are then input into an FEA model to compute stress distribution. Simulations show
that the disc region exhibits surface compressive stress of ~170 MPa and maximum
internal tensile stress of ~73 MPa. At the disc-rib junction, tensile stress reaches ~90
MPa, while the rib area shows tensile stress of 85-95 MPa and compressive stress of
90-120 MPa. Stress varies across subregions of the head. The simulation results are
validated using SCALP-05 photoelastic analysis, confirming their accuracy. This study
provides a foundation for understanding failure mechanisms and optimizing the
tempering process to improve insulator performance. |
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