SEDL / STP / STP918-EB / STP19340S

Analysis of Two Metal-Forming Die Failures

Rich, TP
Associate professor, Mechanical Engineering Department, and assistant professor, Civil Engineering Department, Bucknell University, Lewisburg, PA

Orbison, JG
Associate professor, Mechanical Engineering Department, and assistant professor, Civil Engineering Department, Bucknell University, Lewisburg, PA

Pages: 25    Published: Jan 1986

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Abstract

This case study presents the application of fracture mechanics to analyze the failures of two dies. One is the failure of a die used to swage fittings onto wire ropes. This failure is traced to very high stresses in the die cavity and relatively low fracture toughness; fatigue plays no role. In the second die, the failure is caused by the growth of a crack from the die cavity and is solely a fatigue problem. This die is used to mold gears in a powder metallurgy process.