Malfunction/seizure of 4,000 ton mechanical press involving fatigue fractures of various components

A 4,000 ton mechanical press used to process automotive wheels experienced a sudden malfunction/seizure during routine operation after 44 years. Examination of the press revealed fatigue fractures experienced in two of four support feet, as well as fractures experienced by 22 inch diameter main pins associated with the mechanical drive components. The results of calculations and a finite element analysis will be presented that identified the sequence of component failures that resulted in abnormal loading conditions that resulted in the observed fatigue failures.