DBEM and FEM Analysis of an Extrusion Press Fatigue Failure
This paper presents an application of the Dual Boundary Element Method (DBEM) to the simulation of a fatigue crack propagation affecting the main cylinder of an extrusion press for aluminum sections. The crack initiates at the inner surface of the cylinder and propagates through the thickness causing a leakage of the pressurized oil and consequent production stop. The fatigue load is induced by the pressure variation inside the cylinder as needed to push each section through the extrusion hole. The aim of the simulation is to assess the most probable initial crack dimensions that, after the recorded in service fatigue cycles, lead to the final crack scenario. This was requested in order to assess if there was a rogue detectable flaw introduced by the manufacturing process. For validation purposes, the DBEM numerical results in terms of Stress Intensity Factors (SIFs) in the initial cracked configuration are compared with corresponding Finite Element Method (FEM) results. DBEM SIFs are calculated by both J-integral and Crack Opening Displacement (COD) approaches, whereas for FEM SIFs only COD is used.
KeywordsCrack Propagation DBEM FEM Extrusion Press
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