The Analysis of a Fatigue Failure of a Large Indirect Aluminum Extrusion Press Container Mantle
Gerry J. Dail, P.E., Alcoa Inc.
Track: EXTRUSION PROCESS - Extrusion Process
ABSTRACT --- Extrusion press containers used in the aluminum industry are large,
expensive and geometrically complex components integral to the operation of extrusion
presses and the successful containment of aluminum under high temperatures and
pressures. The design of container assemblies has become increasingly complicated due
to the need for efficient and effective means of removing and servicing these components
without removing the press from operation over extended periods of time. This paper will
present the analysis of a fatigue failure that occurred on a 7300-ton indirect extrusion
press. It will show the failed container, detail the location of the crack initiation site,
analyze the design using finite elements, and show that the failure occurred due to a flaw
in the original design of the assembly. The results of the finite element analysis, coupled
with strain-life prediction of fatigue crack-initiation, will be examined and compared to the
number of pressure-cycles estimated to have occurred prior to the failure of this container
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