Exhaust expansion joints, also known as compensators, are found in a variety of applications such as gas turbine exhaust pipes, generators, marine propulsion systems, OEM engines, power units, and auxiliary equipment. The motion compensators employed must have accomplished the maximum expansion-contraction cycle life while imposing the least amount of stress. Discrepancies in the selecting of bellows expansion joint design parameters are corrected by evaluating stress-based fatigue life, which is challenging owing to the complicated form of convolutions. Meridional and circumferential convolution stress equations that influencing fatigue cycles are evaluated and verified with FEA. Fractional factorial Taguchi L25 matrix is used for finding the optimal configurations. The discrete design parameters for the selection of the suitable configuration of the compensators are analysed with the help of the MADM decision making techniques. The multi-response optimization methods GRA, AHP, and TOPSIS are used to determine the parametric selection on a priority basis. It is seen that weighing distribution among the responses plays an important role in these methods and GRA method integrated with principal components shows best optimal configurations. Multiple regression technique applied to these methods also shows that PCA-GRA gives better alternate solutions for the designer unlike the AHP and TOPSIS method. However, higher ranked Taguchi run obtained in these methods may enhance the suitable selection of different design configurations. Obtained PCA-GRG values by Taguchi, Regression and DOE are well matched and verified for the all alternate solutions. Further, it also shows that stress based fatigue cycles obtained in this analysis for the L25 run indicates the range varying from 1.13 × 104 cycles to 9.08 × 105 cycles, which is within 106 cycles. This work will assist the design engineer for selecting the discrete parameters of stiff compensators utilized in power plant thermal appliances.

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