The Challenge
To investigate the fatigue crack propagation phenomenon affecting the main cylinder of an extrusion press for aluminum sections. The crack had propagated through the thickness, causing a leakage of the pressurized oil and consequent production stop. The fatigue load was induced by the pressure variation inside the cylinder from 0 to 300 bar for each cycle, as needed to push each section of material through the extrusion hole. The main aim of the simulation was to assess the most probable initial crack dimensions that would lead to the final crack scenario experienced in practice.
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