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Failure Analysis of Blade on Coconut Shell Crusher Machine

To cite this article: Surasno and Apriardi Ihlas 2019 IOP Conf. Ser.: Mater. Sci. Eng. 547 012061

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IC-DAEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 547 (2019) 012061 doi:10.1088/1757-899X/547/1/012061

Failure Analysis of Blade on Coconut Shell Crusher Machine

Surasno1*, Apriardi Ihlas2

Center for Material and Technical Product
Jl. Sangkuriang No. 14 Bandung 40135, Indonesia
*E-mail: surasno2005@yahoo.co.id

Abstract. Blade mounted on coconut shell crusher machine was frequently having damaged
while being operated in making of coconut shell powder at small and medium industries. This
took place repeatedly during the operation, therefore blade repairing and replacement has to be
done for every 16 hours at the wear rate of 24.28%. A research was carried out to find out the
cause of damage to the metal blade material on the coconut shell crusher machine. The scope
of this research included the observation on visual examination, dimensions examination,
chemical composition, hardness, and metallography. The results of observations and tests
showed that blade was broken due to abrasion and deformation during operation. The metal
material used for the blade was low carbon steel. Chemical composition of the metal content of
the blade were: C (0.103 up to 0.144 %) and Mn (0.657 up to 1.400 %). Hardness value of
blade metal materials were 146 up to 148 Hv. Microstructure consisted of ferrite and pearlite.
This low carbon steel material is not suitable to be used as a blade on coconut shell crusher
machines for producing of coconut shell. Repairing and maintenance of welding coating
methods on blades using low carbon electrodes does not give increased significant value of
hardness. Blade replacement in coconut shell crusher machines must comply with the
requirements of tool steel with suitable heat treatment or the use of low carbon steel with the
carburization process.

Keywords: blade, coconut shell machine, low carbon steel, failure analysis

1. Introduction
Coconut shell powder at small and medium industries as seen in Figure 1 was an organic
fiber to be used in the manufacture of mosquito repellent. This material is flammable, but
burnt out slowly. The process of making coconut shell powder uses a coconut shell crusher
machine with 150 HP and a 3.100 rpm engine speed. In this machine, 16 blades were used to
rotate and grind the coconut shells into fine crusher. Each coconut shell crusher machine has
a production capacity of 1 ton/day of coconut shell powder and every day operates 16 hours.
(See Figure 2).

Figure 1. Coconut shell powder (left) [1] and Mosquito repellent (right) [2]

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IC-DAEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 547 (2019) 012061 doi:10.1088/1757-899X/547/1/012061

Figure 2. Mosquito coil factory

The use of blades on coconut shell crusher machines is often a failure, resulting in a decrease
in lifetime of blade. Thus the steel material is not suitable to be used as a tool steel material,
because the blades must be replaced and repaired frequently. This is an obstacle for machine
operators and company expenses. Therefore, the inappropriate use of metal blade material is a
case of failure that must be analyzed.

Investigation of failure analysis is a research process to determine the causes of failure of a

production equipment through: investigation of steel materials used for blades, investigation
of the operation of coconut shell crusher equipment operated by factory operators,
investigation of blade designs installed on machine tools coconut shell crusher, and operating
environment investigations on the durability of steel materials used [3].

This research will be focused on steel blade materials on coconut shell crusher machines that
have been damaged and are still new (See Figure 3). Broken blade can occur due to the use of
metal as an unsuitable blade raw material. This is indicated by the appearance of defects on
the blade surface as an impact of improper abrasion process resulting in a shorter lifetime
using this blade [4].

Abrasion is the initial phenomenon of damage to the blade steel surface by removal and
release of friction material [5]. Abrasion occurs on the surface of the blade material when
particles of organic material, stone, or sand rub against the surface of a blade steel material
that rotates in a coconut shell crusher machine. The process of abrasion and collision of blade
surface due to the rotation of the coconut crusher machine affect the blade weight and
dimensional reduction progressively [3, 10].

Figure 3. Blade mounting position

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IC-DAEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 547 (2019) 012061 doi:10.1088/1757-899X/547/1/012061

Changes in the dimensions of the blade due to the abrasive process cause unstable rotation
and the occurrence of collisions/impacts of two different materials, so that there will be
deformation on the surface of the blade surface in contact with different levels of deformation.
Normally, wear problems are different from direct damage. Wear of hard metal parts produces
a smooth surface, glides or rolls with pressure on the surface [6].

The surface of the metal material with low hardness value is easier to undergo an abrasion [3].
The chemical composition of carbon steel with low carbon and manganese will not raise
significant hardness even though the heat treatment process is carried out [7]. Blade repair by
coating the surface using the SMAW welding process using filler metal electrode RB-26
(Kobe Steel) as a metal surface welding surfacing hardener, the blade hardness value remains
low [8]. The abrasion process of the blade surface is generally uneven will affect the rotation
of the engine imbalance and will accelerate surface deformation by the process of pounding
and collision [9]. From the problems faced by the manufacturer of coconut shell crusher, it
is necessary to conduct research to improve the performance of coconut shell crusher
machines.

2. Materials and Methods

The blade material used for this research is a broken blade material and a new blade material
equivalent to low carbon steel AISI 1010.

Figure 4. Difference between used blades and new blades

The research was carried out through visual observation on the surface of the damaged blade
(existing) and visual observation of the blade before being used as a comparison. The purpose
of this observation was to obtain an overview of broken blade from observing the cross-
section surface of the broken section.

The purpose of a macrostructure examination is to observe the cross section of a blade,

compare a new blade and a broken blade, as well as the welding treatment of a broken blade.

Chemical composition examination using spectrometer was objected to determine the element
of the basic metal composition of the blade, the composition of the chemical elements of the
blade material as a basic for determining the type of parent metal material used, whether it is
suitable to be used as a coconut shell crusher. Chemical composition testing was carried out
on both coconut shell crusher machine blades which were new and damaged.

Testing the hardness of the cross section of blade was carried out by means of the Vickers
Hardness test. Hardness value were used as a consideration for the performance of coconut
shell cutting tools, compared it with the hardness of tool steel. Hardness test were mainly
carried out on welded surfaces. In addition, hardness test was also carried out on the two
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IC-DAEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 547 (2019) 012061 doi:10.1088/1757-899X/547/1/012061

parent metals to estimate the correlation between hardness values and the value of chemical
composition, especially carbon and manganese content. The test was carried out using the
Vickers method with a load of 10 kgf.

Metallographic observation by means of an optical microscope was conducted to determine

the type of microstructure of metal materials for new blades and material of broken metal
blade.

3. Results and Discussion

Visual examination
After 16 hours of use, all coconut shell crusher blades were damaged in the form of wear,
abrasion and deformation (See Figure 5). Therefore, every blade usage always uses the new
one or that has been repaired. Visual examination on the surface of the blade of coconut shell
crusher indicated wear defects of the surface (surface abrasion) and deformation. Due to the
wear abrasion, surface erosion has occured (See Figure 4). Deformation defects and surface
wear on the damaged blade, in the form of surface digestion, estimated by metal blade
material with low hardness.

Figure 5. Texture of blade after the abrasion process

Coating weld of the back side and the sharp side of the blade by SMAW welding process with
electrode of RB 26 kobe steel (See Figure 6). Welding patches on sharp parts are intended for
direct collision with coconut shell product, appear to be damaged due to abrasion and
deformation by strong friction. The abrasion resistance and strength of the metallic material of
the weld layer on the blade is insignificant.

Figure 6 Welding layer on the blade

The bolt hole for tightening is deformed which can occur by the force of pounding from the
imbalanced engine speed. This phenomenon may be due to the uneven blade surface abrasion
resulting in changes and different sizes. The unstable rotation generate the pounding which
resulting in deformation. Uneven blade abrasion resulting in unstable engine speed, so that
deformation arises in the bolt hole of the blade.

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IC-DAEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 547 (2019) 012061 doi:10.1088/1757-899X/547/1/012061

Dimension reduction
The initial dimensions of blade on the coconut shell crusher machine was trapezoidal shape
as seen in Figure 5. After the coconut shell crusher machine was operated for 16 hours there
was a reduction in the size of the blade thickness of 7 mm, the size of the blade thickness was
originally 14 to 8 mm thick, while the reduction towards the blade width is 20 mm, from
original size of 70 to 50 mm.

V3 lb

tb
D

V4
V1
pb

V2

ptot la

pa ta

Figure 7. The dimension of crusher blade

Weight reduction
From figure 4 and 7, the new coconut shell crusher blade (1) and broken coconut shell crusher
blade (2) were obtained:
- ptot1 = 389 mm, (pa1 = 309 mm, pb1 = 80 mm),
la1 = 14 mm, lb1 = 19 mm,
ta1 = 30 mm, tb1 = 70 mm.
- Hole diameter, D = 22 mm, r = 11 mm.

V = V1 + V2 + V3- V4
= (½ (pa x (tb-ta)) x la) + (pa x la x ta) + (pb x tb x lb) - (pi x radius2 x lb).

Volume is obtained for the new blade, Vnew = 328.850 cm3 = 0.00032885 m3.

In the mass measurement for the new blade, (Mnew ) = 2.9 kg.
Then the density of the blade material, ρnew = 8,818.61 kg/m3.
Since the new and damaged blade is the same material, (ρbroken = ρnew = 8,818.61 kg/m3)

To measure the volume of an irregular surface,

calculate mass of the broken blade i.e, Mbroken = 2.2 kg., then:

Vbroken = Mbroken/ρbroken = 0.000249 m3.

These the dimension reduction on the broken blade is,

ΔV = ((V_new-V_broken) / V_new) x100%, ΔV = 24.28%.
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IOP Conf. Series: Materials Science and Engineering 547 (2019) 012061 doi:10.1088/1757-899X/547/1/012061

Loss of weight and dimensions resulting in damage to all blades as many as 16 pieces
mounted on the coconut shell crusher machine after the machine is operated. Similarly, the
high of coconut shell hardness affect the deformation and abrasion of the surface of the blade
metal due to impact and friction with low carbon steel surfaces. The hard coconut shell and its
non-uniform dimensions are the obstacles to the operation process of making coconut shell
crusher which affect the unstable collisions so that the deformed blade bolt hide occured
(Figure 5).

Macrostructure
Macrostructure testing results showed that the cross section of the new blade was rectangular
(Figure 8a), while that of broken blade has decreased in thickness and width after 16 hours of
operation (Figure 8b).
Broken blade material has been welded and subjected to abrasion during use and deformation
of the bolt hole, and no indication of heat treatment. It was known that improper repairing has
been applied.

Figure 8a. Cross section of the New Blade Figure 8b. Cross section of the Broken Blade

Chemical Composition
The chemical composition of blade is shown in Table 1. New blades and broken blades
include low carbon steel groups (AISI/SAE 1010 standard). The broken blade contain of
higher carbon compared to new blade.

Table 1. Chemical composition of blade

No. Elements New blade, % Broken blade, % AISI 1010, %
1 Carbon 0.103 0.144 0.08-0.13
2 Silicon 0.233 0.359 0.15-0.35
3 Manganese 0.657 1.40 0.30-0.60
4 Phosphor 0.0156 0.0132 ≤ 0.040
5 Sulfur 0.0056 0.0034 ≤ 0.050
6 Chrom 0.0094 0.0158 ≤ 0.20
7 Molibdenum 0.00049 0.00057 -
8 Nickel 0.0134 0.0158 -
9 Aluminium 0.0343 0.0325 -
10 Cupper 0.0142 0.0118 ≤ 0.25
11 Vanadium < 0.0001 <0.0020 -
12 Wolfram < 0.0002 <0.00020 -

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IOP Conf. Series: Materials Science and Engineering 547 (2019) 012061 doi:10.1088/1757-899X/547/1/012061

Hardness
Hardness of the new and broken blades are presented in Table 2. Hardness of new blade cross
section was in the range of 117-123 Hv, while the hardness of the broken blade cross section
included the base metal (BM) zone (146-148 Hv), HAZ (152-154 Hv) and the weld metal
(WM) zone (171-179 Hv). The welding process resulting in the difference of blade hardness.
Hardness of the blade with BM is lower than that of WM and HAZ. The highest hardness was
found in the WM zone. High increase in hardness was occured due to an increasing in heating
welding process. The low value of hardness of new blade cross section compared to that of
broken one were due to the higher content of carbon in broken blade.

Table 2. New and broken blades

No. New blade Broken blade
1. 118 (BM) 179 (WM))
2. 117 (BM) 171 (WM)
3. 123 (BM) 152 (HAZ)
4. 154 (HAZ)
5. 146 (BM)
6. 148 (BM)

Microstructure
The microstructure testing results showed the presence of ferrite and pearlite with the grain
size of 8 (See Figure 9). Pearlite compounds tend to be much more in the broken blade; this
comply with its higher carbon content. The change in microstructure for welded broken blade
was due to the heat effect in the parent metal zone by welding process.
The microstructure of ferritic was found in the WM zone with the grain size of 9 which were
finer than its parent metal. This will contribute to the higher hardness of broken blade.

Figure 9. Microstructure of new blade (left) and broken blade (right)

Figure 10. Photograph of the broken blade microstructure WM (left), MW-dilution-HAZ

(middle), HAZ-BM (right)

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IC-DAEM 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 547 (2019) 012061 doi:10.1088/1757-899X/547/1/012061
Blade repair and maintenance by welding SMAW using low carbon steel electrodes does not
improve its performance.

4. Conclusions
1. Blade failure in coconut shell machine were occured due to abrasive wear and
deformation for every 16 hours operation at the wear rate of 24.28%.
2. The use of low carbon steel material AISI 1010, is not suitable for coconut shell
machine blade. The low of hardness as well as its microstructure of ferrite pearlite will
not be resistant to abrasion and impact.
3. Heat treatment of blades from low carbon steel materials will not increase the value of
hardness.
4. In order to improve the materials blade for coconut shell crusher machines, it is
recommended to use steel materials suitable for heat treatment tool steel (M3, M4, or
M10) for increased abrasion resistance or using low carbon steel with carburizing
hardening heat treatment [13, 14].

5. Acknowledgements
The authors would like to express gratitude to the Center for Material and Technical Product
(B4T) and PT. Indratma Sahitaguna which have supported this research. We would like to
thank our colleagues and technicians who have assisted conducting this research. We would
also like to thank Mr. Kosasih as Head of Technical Inspection B4T for the assistance in
discussion and analysis as well as Mrs. Wieke Pratiwi as senior researcher for comments to
improve the manuscript.

6. References

[1] Coconut shell powder, 12 March 2014, http://aliranalam.blogspot.com/2014/03/tepung-

batok-kelapa.html.
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nyamuk.html.
[3] A. Srithar, K. Palanikumar, and B. Durgaprasad, “Experimental Investigation and
Surface roughness Analysis on Hard turning of AISI D2 Steel using Coated Carbide
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[4] V. Ratia, I. Miettunen, and V. Kuokkala, “Surface deformation of steels in impact-
abrasion : The effect of sample angle and test duration”, Wear, vol. 301, no. 1–2, pp.
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[5] S. Schuldt, G. Arnold, J. Roschy, Y. Schneider, and H. Rohm, “Defined abrasion
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IOP Conf. Series: Materials Science and Engineering 547 (2019) 012061 doi:10.1088/1757-899X/547/1/012061

[10] T. Materials, ASM Handbook Vol 11. “Failure Analysis of Prevention”, Printed in the
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