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During mounting of the coupling, the parts will have to deform. This is not easy in your design. If you make slots in the female part, this will be easier. See as an example this feston plug that I designed. https://cults3d.com/en/3d-model/tool/festool-plug-20mm

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The modulus of elasticity of the vulcanized rubber is in the range of 218psi that compared to 9990ksi of 6061 aluminum alloy negates any concerns about the difference in thermal expansion. But the ratio of the radius to the wall thickness of approx 25, classifies the pipe as a thick wall and we use thick wall cylinder formulas. For the Excel spreadsheet, ...

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If this nails your problem, I want to play bass on your release. To split an extruded tube indicates two things: 1) severe overpressure, in excess of the yield point hoop stress quoted above, OR 2) defective extrusions. Let's look at each. Rubber is far, far more compliant than aluminum. This suggests to me that the "bulk" overpressure during the ...

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If the extruder has a die in the exact shape you're wanting, it might be worth asking them. If you can get past the extruder's quote filter (our's is at hundreds of thousands of pounds per year), if they don't have a die for the part you're wanting, you'll be buying an extrusion die (think $3k -$6k). Do you want close tolerancing, that'll be extra. ...

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You just need to calculate the hoop stress of a cylinder. The formula is really easy: $$\sigma =\frac{p r}{t}$$ where: $\sigma$: is the hoop stress $p$: the pressure $r= d/2$ : the radius of the tube (I would ignore the ovality if its small) $t$: the thickness of the tube.

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