Our project involves investigations on the failure of an 8000 ton heavy duty press. This press is used for forming boiler drums by U-shell pressing operation. The failure of the press had occurred due to formation of several cracks in the upper tool part of the press. Initially the detailed three dimensional model of the upper tool is developed using the popular solid modeling package, Pro/E. Later meshing of the model is done in Hypermesh and analysis of the meshed model is carried out using the analysis package Ansys 8.0. The upper tool of the press has been analysed using After getting the stresses and strain values in the upper tool body from the analysis, the expected low cycle fatigue life of the press is predicted using the Coffin-Manson’s relations. These investigations have clearly brought out the cause of the failure of the press. The upper tool part of the press has a finite life design as regards cold correction operations, and, low cycle fatigue is the life consuming mechanism responsible for its failure. Further recommendations are made for extension of life of upper tool part of press by way of stiffening. The scope of the work is further enhanced by finding the real stress distribution and strains existing in the upper tool by Neuber’s approximation method. Thereafter the reliability of the method is discussed. 1
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