You are on page 1of 34

Applied Failure Analysis

Greg Rentfrow Empire Machinery Mesa, Arizona

Failure Analysis
The thoughtful review of product and environmental facts which leads to the identification of root causes of product problems.

2

Failure Analysis
8 Steps of Failure Analysis
1. Define the problem 2. Organize the fact gathering 3. Observe and record the facts 4. Think logically with the facts 5. Identify the most probable Root Cause 6. Communicate responsibility 7. Make repairs as directed 8. Follow up

3

Failure Analysis • All failures must be carefully analyzed. 4 . To prevent reoccurrence. • No matter how large or small. something different must be done.

5 . Both your`s and our`s Some failures can be traced back to a previous incidence that occurred long before the final failure.folders and reports. Fracture road signs will tell.Failure Analysis History Check files.

Make Changes • Design • Service Procedures • Machine Monitoring • Maintenance practices • Training 6 .

Scavenge sump. 7 . Severe corrosion.Failure Analysis D9L Landfill application. Failed all engine main bearings. Root cause: No or Poor maintenance Did not clean belly pan!! Fix: Made change to belly pan mounts.

Failure Analysis 8 .

Failure Analysis 9 .

Organize • • • • • • Don’t destroy the facts Gather and label ALL parts Take an oil sample / oil quality? Save the filters and screens Gather machine service history Talk with operator / mechanics 10 .

Failure Analysis • • • • • • History folder Wear types Fracture types Load types Temperatures Electronic control module information Observe & Record 11 .

part was left in service until maximum life.90% Adhesive-Fastest Corrosion Erosion Fretting corrosion Contact Stress Fatigue (Normal at high hours with heavy loads) What you should see at PCR.Wear Types • • • • • • Abrasive . 12 • .

(Abnormal) nick from torch.) • Initiation site (start of fracture) • Final fracture (end of fracture) • Shear lip (end of ductile fracture) • Fast crack (brittle or ductile) • Slow crack (fatigue) 13 . wear at a snap ring groove. bearing radius. keyway.Terminology • Stress raisers(normal) physical irregularity. geometry change. spline area transition. snap ring groove. dent from handling damage.

Failure Analysis Fracture Types • Brittle • Ductile • Fatigue 14 .

.Fatigue Fracture • Light to dark • Smooth to rough • Ratchet marks • Beach marks 15 Ratchet marks indicate that very high stresses (loads) were present at the initiation site to start a Fatigue fracture at a normal high stress area( root fillet).

Failure Analysis Bending Fatigue 16 .

but not always as seen here on this hydraulic cylinder rod. 17 .Fatigue Fracture Beach Marks usually radiate away from the initiation site.

Brittle Fractures • Fast (one time overload) • Crystalline (sparkles) • No plastic deformation 18 .

Failure Analysis Brittle Fracture 19 .

Failure Analysis Brittle Fracture Chevrons 20 .

Failure Analysis Ductile Fractures • • • • • Fast Large shear lips Dark Rough & woody Plastic deformation 21 .

Failure Analysis Fractures Ductile • Plastic deformation • Necking 22 .

Failure Analysis Factors Affecting Ductile Fractures • • • • Medium .low hardness High temperatures Low stress concentration Low load rate 23 .

Think Logically • How does it work? • How does it load? 24 .

What Do You See? Beware of Preconceived Ideas 25 .

Failure Analysis Root Cause • Identify root cause • Redefine problem 26 .

Communicate with the responsible party • 7.Failure Analysis • 6. Make repairs 27 .

Failure Analysis • Follow-up • Maintenance practices • Operating techniques Final Steps 28 .

Failure Analysis Use the monitoring systems to your advantage • • • • • Caterpillar Monitoring System CMS ET VIMS VIDS 29 .

Repair Before Failure Your Past Experience!!! – – – – CTS SOS OMG CSA Customer Track Service Scheduled Oil Samples Overhaul Maintenance Guide Customer Support Agreements 30 .

Failure Analysis Repair before failure….maximize profit margin 31 .

Failure Analysis • Preventive Maintenance Predictive Maintenance • PM could also mean – Preserving money – Peace of mind 32 .

Our Goal Is to provide Excellence in Service & Equipment to Keep`em Productive while Reducing cost. 33 .

Applied Failure Analysis CUSTOMER FACTORY DEALER 34 .