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<p>Flexible pipes are growing in popularity every day due to their compatibility with severe loading and environmental conditions. The carcass layer is employed in case of high external pressure, which increases with water depth. Due to the interlocked helical structure of the carcass layer, a noticeable amount of residual stress is generated in the structure during the manufacturing process. In this paper, a radial compression test is conducted, and the results are compared with those of a numerical model built using ABAQUS software. The results show that neglecting manufacturing-induced residual stress leads to an overestimation of the radial compression response by approximately 10% compared with experimental measurements. The findings highlight the necessity of incorporating the residual stress generated during the metal forming process into numerical simulations for more accurate prediction of structural performance. The approach outlined in the current work provides a foundation for future studies and improved design of flexible risers.</p>

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Experimental and numerical investigation of metal forming–induced residual stress in flexible pipe carcass layers

  • 期刊论文

  • 发表日期：

    2026年2月12日

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  • Mohsen Saneian,
  • Yuteng Zhang,
  • Pan Fang,
  • Yong Bai

摘要

Flexible pipes are growing in popularity every day due to their compatibility with severe loading and environmental conditions. The carcass layer is employed in case of high external pressure, which increases with water depth. Due to the interlocked helical structure of the carcass layer, a noticeable amount of residual stress is generated in the structure during the manufacturing process. In this paper, a radial compression test is conducted, and the results are compared with those of a numerical model built using ABAQUS software. The results show that neglecting manufacturing-induced residual stress leads to an overestimation of the radial compression response by approximately 10% compared with experimental measurements. The findings highlight the necessity of incorporating the residual stress generated during the metal forming process into numerical simulations for more accurate prediction of structural performance. The approach outlined in the current work provides a foundation for future studies and improved design of flexible risers.