The fundamental design of high pressure joints such as crosses and tees has remained the same for many years. However, the introduction of commercially available high pressure equipment operating at 600 MPa and higher has demanded improved designs for these classic connections. This study presents a new design concept for reducing the stress concentration at intersecting crossbores. Both the finite element analysis and the fatigue test results from the standard high pressure design and the new design are compared. The new approach realizes a 17–25% reduction in the stress concentration factors and a 40% improvement in fatigue life test results when compared to the standard design.

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