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Failure Analysis of Conveyor Chain Links: A Case Study

Article · December 2013

DOI: 10.4028/www.scientific.net/AMM.465-466.725

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Applied Mechanics and Materials Vols. 465-466 (2014) pp 725-729 Online: 2013-12-19
© (2014) Trans Tech Publications, Switzerland
doi:10.4028/www.scientific.net/AMM.465-466.725

Failure Analysis of Conveyor Chain Links: A Case Study

Nur Ismalina Haris1,a, Md Saidin Wahab1,b, Amarul Talip2,c
1
Faculty of Mechanical and Manufacturing Engineering, Universiti Tun Hussein Onn Malaysia,
86400 Parit Raja, Batu Pahat, Johor
2
School of Manufacturing Engineering, Universiti Malaysia Perlis, Kampus Alam Pauh Putra,
02600 Arau, Perlis
a
nurlyena@gmail.com, bsaidin@uthm.edu.my, camarul@unimap.edu.my

Keywords: chain links, defects, failure analysis

Abstract. This case study is to investigate the causes of failure of chain system through
characterization on the failure component. The failures that occur are relate to welding because this
dipping latex industry used customized chain that have to be weld in joining with outer chain links.
The analysis revealed that the weld defect such as crater leads the crack propagation and added with
cyclic loading that cause the fatigue failure. The fatigue failure occurs due to this generated crack at
the outer circumference of the weld within chain attachment and outer chain links plate. This type
of defect also can be categories as designing-in defect. Fatigue crack propagation was evident by
progressive beach marks and the scanning electron microscopy (SEM) analysis revealed the types
of microstructure that resulting at heat affected zone (HAZ). Hardness testing by using Rockwell
Tester found the different hardness profile at three areas that are weld metal, base metal and heat
affected zone. The maximum hardness values were found at heat affected zone and weld metal.
Finite element method (FEM) that is Ansys Workbench was used to review the different size of
outer link plate thickness that affected to the stress distribution. It was found that stress can be
minimized with increasing the plate thickness.

Introduction
Chain conveyors are those particular types of conveyors, which are continuously playing an
important role in various industries [1]. Referring to [2], chain conveyor was excellent in bulk
handling, unit handling, dust in conveying bulky goods and need small space requirement compared
with belt and roller. Usually, there are five types of chains that are cast iron chain, cast steel chain,
forged chain, steel chain and plastic chain. Nowadays, one of the largest shares of chain that being
produced is steel chain or commonly called roller chain [2]. Top Glove Corporation Berhad is a
rubber manufacture that used roller chain conveyors to transport products from one place to
another, and is a part of the manufacturing process. The most problem that was often encountered
by the company in production process is the failure of chain links conveyor to operate as desired.
Previous literature state that failures can be caused by [3, 4]:
i. Designing in defects
ii. Manufacturing in defects
iii. Operating in defects
iv. Environment in defects
So, this case study will help the industries to identify what types root of failures of their chain
conveyor and how to prevent the failures for next time.

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726 4th Mechanical and Manufacturing Engineering

Experimental investigation
Experimental investigations were conducts on sample of failed chain links conveyor such as
in Fig. 1 (a) and (b).

Fig. 1: (a) Failed chain links (b) Overlapping of the crack

Chemicals composition and mechanical properties

Chemical analysis of the chain links sample, Table 1, was carried out by using SEM with
EDX TM3000. The composition data shows that the failure sample (in between special attachment
and outer link plate) was type of low carbon steel.
Table 1: Chemical composition of the chain link material (0.19 wt. %C)

C% Si% Mn% P% S% Al% N% Nb% Ti%

0.19 0.23 0.4 0.024 0.015 0.09 0.009 0.04 0.03

According to the specified chemical composition as stated in Table 1, we can identify

percentage of carbon equivalent by using two widely used formula, that are Pcm and CEq. [5]
develop Pcm formula as below Eq. 1:
% % % % % % %
Pcm % = C% + + + + + + 5B (1)

= 0.218 %
Meanwhile by using CEq formula Eq. 2, that developed by [6]:

% % % % % % %
CEq % = C% + + + + + (2)

= 0.224%

Referring to group of carbon equivalents for the assessment of weldability, this both number
of carbon equivalent was grouped in Group B that has carbon as more important than the other
alloying elements and is more applicable to modern steels [7], So, the weldability of chain links
samples based on Pcm and CEq can be define as excellent [8].
Hardness testing of failure sample was conducted by using Rockwell hardness tester and the
result as shown in Table 2. Meanwhile, Fig. 2 shows the hardness distribution in different zones and
the range of hardness values are within 98-101.1 HRB. The maximum hardness was found at heat
affected zones (HAZ) and weld metal (WM) area.
 Applied Mechanics and Materials Vols. 465-466 727

Table 2: Hardness distribution of sample

Position 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
HRB 98 98.5 98.8 98.9 99.3 99.5 100.3 100.5 101.1 101 100.9 100.8 100.2 100.2 100 100.3 100.1

Fig. 2: Weld metal, heat affected zone and base metal hardness profiles on surface

Metallographic analysis
Chain links sample then be cut to analyse the microstructure that present by using Scanning
Electron Microscope (SEM). This chain links has two major constituents, which are ferrite and
pearlite as in Fig. 3.

Fig. 3: Micrograph of low carbon steel. Etched 2% nital

Widmanstatten ferrite, acicular ferrite and allotriomorphic ferrite was found occurs in the
heat affected zone (HAZ) as shown in Fig.4a. The coarse grained region of the HAZ is adjacent to
the weld fusion zone and contains grains larger than those in the base material as shown in Fig. 4b.

Fig. 4: Microstructures in HAZ (a) Widmanstatten ferrite, acicular ferrite and allotriomorphic ferrite
(b) Coarse grained HAZ at weldment

Identify stress distribution caused by external load

Literature [9] stated that chain link is one of the most stressed zones. The chain links stress
then is calculated by applying finite element method (FEM) with Ansys Workbench. Fig. 5 (a)
shows that stress distributions appear at U-bracket, at joint within outer chain links plate and
attachment also a few places at inner chain links plate. This simulation shows that one of the most
728 4th Mechanical and Manufacturing Engineering

critical area that to be confronted with failures are joining within outer chain links plate and
attachment (Fig. 5b). This finding was confirmed by the failure of chain links that took place at the
weld area after a short service life and the fatigue was initiated due to generated defects at the outer
circumference of the weld. Previous literature [10] prove that the vast majority of component
fatigue failures take place at the welded connections when the welded structures subjected to fatigue
and impact loading.

Fig. 5: (a) Stress distribution in chain links (b) Stress distribution at weld area

Proposed improvement on chain (overcome the failure)

To overcome this problem, the stress distributions that occur around the weld area must be
minimized as much as can. Regarding to literature [11], the static tensile load, Ft was applied in
different thickness of outer chain links plate and Fig. 6 shows the stress distribution in normal outer
link plate with thickness 6mm.

Fig. 6: Stress distribution in outer link plate 6mm

Table 3 shows the maximum Von Mises stress value that obtained and plotted into graph as shown
in Fig.7.
Table 3: Outer link plate thickness and Von-Mises Stress
Plate thickness (mm) Equivalent (von -Mises) Percentage Difference
Stress (MPa) (%)
6 20.998 -
6.5 (Normal) 19.120 -
7 17.931 6.42
7.5 16.963 11.96
8 15.679 19.78
 Applied Mechanics and Materials Vols. 465-466 729

Fig. 7: Equivalent Von-Mises Stress graph

Normal thickness of outer link plate is 6.5mm and the maximum stress distributed is 19.120
MPa. For thickness 7mm, the stress distributed is 17.931 MPa and percentage difference with
normal plate is 6.42%. While for 7.5mm, the stress distributed is 16.963MPa with 11.96% and for
thickness 8mm the stress distributed is 15.679MPa with 19.787%. This findings show that the
thicker outer link plate have low stress distribution than the normal thickness (6.5mm).
Conclusion
The results that obtained suggest that the major causes of chain failure are types of welding
at joint design, weld defects and don’t have weld treatment to improve weld strength. Referring to
[3, 4] can conclude that the type of failure that exist at conveyor chain links is designing-in defects.
Decreasing the outer plate thickness can minimize the stress that can interrupt the weld strength and
contribute to the failure.
References
[1] M. Singh and M. Singh, "Chain Conveyors have and can improve the efficiency of many
industrial processes," 4 Oct 2012. [Online]. Available:
http://www.neoconveyors.com/blog/chain-conveyors-have-and-can-improve-the-efficiency-of-
many-industrial-processes/. [Accessed 10 Dec 2012].
[2] K. Otoshi, "The complete guide to chain," 1997. [Online]. Available: http://chain-guide.com/.
[Accessed 12 Nov 2012].
[3] C. Gagg, "Failures of components and product by 'engineered in defects'," Engineering Failure
Analysis, p. 212–222, 2005.
[4] S. Bosnjak, M. Arsic, N. Zrnic, M. Rakin and M. Pantelic, "Bucket wheel excavator: Integrity
assessment of the bucket wheel boom tie-rod welded joint," Engineering Failure Analysis, p.
18:212–22, 2011.
[5] Ito Y. & Bessyo K., "Weldability Formula of High Strength Steels: Related to Heat-affected
Zone Cracking," International Institute of Welding, 1968, pp. Doc IX-576-68.
[6] C. F. Düren, "Prediction of the hardness in the HAZ of HSLA steels by means of the C-
equivalent," Conference on Hardenability of Steels, p. Paper 4, 1990.
[7] N. Yurioka, "Carbon equivalents for hardenability and cold cracking susceptibility of steels,"
Conference on Hardenability of Steels, p. Paper 3, 1990.
[8] Ginzburg, Vladimir B.; Ballas, Robert, "Flat rolling fundamentals," CRC Press, 2000, p. 141–
142.
[9] D. Momčilović, N. Hut, L. Milović and I. Atanasovska, "FAILURE ANALYSIS OF CHAIN
BRACKET," New Trends in Fatigue and Fracture, pp. 123-126, 2011.
[10] J.M. Barsom, S.T. Rolfe, Fracture and fatigue, ASTM Publications, 1999.
[11] V. Kerremans, T. Rolly, P. D. Baets, J. D. Pauw, J. Sukumaran and Y. P. Delgado, "Wear of
conveyor chains with polymer rollers," Sustainable Construction and Design 2011 , 2011.
 4th Mechanical and Manufacturing Engineering
10.4028/www.scientific.net/AMM.465-466

Failure Analysis of Conveyor Chain Links: A Case Study

10.4028/www.scientific.net/AMM.465-466.725

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