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The issue was examined for corrugated compensators experiencing fatigue failure in high-pressure pipelines with complicated operating circumstances. A finite element model was established for stress simulation of the corrugated compensator under coupled load containing internal pressure and axial force. And a method was proposed to calculate the stress concentration factor using path integral. The corner area of the corrugated compensator was predicted to be a risky location for the fatigue crack sprouting. By carefully taking into account Goodman average stress correction, stress concentration factor, surface treatment procedure, load form, etc., the fatigue life prediction model of corrugated compensator was developed with multiple factors correction, and the values of each correction factor were obtained. According to the prediction model, the corrugated compensator's fatigue life prediction had a divergence of less than 10% from the engineering measured data. This result provides theoretical guidance for fatigue life assessment and design optimization of corrugated compensators in engineering applications.
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