Numerical Simulation and Analysis of the Manufacturing Process of Pre-Bulged Rupture Discs

Rupture discs, also known as bursting discs, are indispensable components in fluid-operated systems providing effective protection against hazardous over-pressure or partial vacuum. They belong to a special class of safety devices and are found in a variety of technical applications including pressure vessels, piping systems, reactors and boilers. In all application scenarios, rupture discs act as sacrificial parts that have to fail precisely at a predetermined differential pressure, opening a relief flow path for the working fluid. The membrane employed within rupture discs is usually made out of specific metal alloys or different material layers depending on the particular application. However, for many manufacturers of rupture discs, the production process is characterized by a lack of systematic procedures, relying instead on trial and error as well as empirical values. By means of thorough finite-element-based modeling and simulation of the bulge-forming process of rupture discs, including an elastic–plastic material law, large deformation, as well as contact mechanics, it is possible to accurately predict the resulting stress–strain behavior. All simulation results are rigorously validated through corresponding experiments conducted during the bulge-forming process. Therefore, this contribution provides a reliable basis for the parameter set-up during the manufacturing process of rupture discs.