FAILURE ANALYSIS & DESIGN

COURSE CODE: 19MEE332

NAME: REDDIPALLI KAUSHIK DORA
ROLL NUMBER: CB.EN.U4MEE19232
1. Fracture failure analysis of high-speed shaft
Facai Ren1 , Xinghua Wu1 and Xiaoying Tang1 1Shanghai Institute of Special Equipment Inspection and Technical Research,
Shanghai 200062, PR China.

 Abstract: The fracture failure causes of a high-speed shaft in a hoisting gearbox were analyzed
based on the optical microscope and scanning electron microscope analysis. The results show
that the fracture failure cause of the high-speed shaft is fatigue. Surface defects, such as
machining tool marks and folded cracks, are the source of fatigue fracture under stress.
 Introduction: During the loading and unloading of a portal crane, the high-speed shaft of the
hoisting gearbox suddenly broke, causing the damage of the adjacent rod teeth. In order to avoid
similar accidents, it is necessary to systematically analyze the causes of fracture of high-speed
shaft. In this paper, the fracture failure analysis of a high-speed shaft was carried out. The
chemical composition, metallographic and SEM micromorphology of the shaft were analyzed.
 Methodology: The macroscopic morphology of the high-speed shaft of a hoisting gearbox is
shown in Fig. 1. The fracture position is at the withdrawal groove with variable cross section, as
shown by the arrow in the figure. The section is perpendicular to the axis. The machined surface
at the corner transition is very rough, and deep machined tool marks can be seen visually. The
material of the high-speed shaft is 20CrMnTi
 The macroscopic morphology of fracture surface is shown in Fig. 2. It can be seen that the whole fracture has no
obvious plastic deformation and the fracture is even. There are strong friction marks on the fracture surface. The
(a) zone has bright color and is the source of fatigue. The (b) zone is smooth and fatigue extension zone. The (c)
zone is transient breaking area.
 CHEMICAL COMPOSITION:

 SEM Micromorphology analysis:

 Conclusion:
The results of chemical composition analysis show that the components of the material meet the requirements of
20CrMnTi steel in relevant standards. Fracture macroscopical examination and scanning electron microscopic
analysis show that the fracture failure cause of the high-speed shaft is fatigue. Machining tool marks and surface
defects of folded cracks will lead to stress concentration in the region, and become the source of fatigue fracture
under stress.
 2. Failure analysis of a crane gear shaft
Goran Vukelica , D. Pastorcicb *, G. Vizentina a University of Rijeka, Faculty of Maritime Studies, Marine Engineering Department, Studentska 2, 51000
Rijeka, Croatia bUniversity of Zadar, Maritime Department, Zadar, Croatia

 Abstract: This research deals with a teeth failure of a gear shaft that served as a part of shipyard crane drive train.
Almost all of the teeth of a spiral bevel gear, part of a larger shaft, fractured during normal operation of the crane.
 Introduction: Gears are almost unavoidable components of every machine. Their application ranges from
transmission systems in automotive, plane and marine industry, to special applications in power generating and
processing plants. Gears design ranges from simple to sophisticated gear pairs and, along with their complexity,
rises the need for thorough understanding of acting stresses and, consequently, possible failures.
 Experimental procedures:

Visual observations-A gear shaft that serves as a part of shipyard crane drive train failed with 15 of its 17
helical teeth damaged. It is a spiral bevel gear, part of a larger shaft. Spiral bevel gears find their main
application vehicle differentials, where the direction of drive from the drive shaft must be turned 90 degrees to
drive the wheels. Design that is characterized by the helical teeth is capable of providing less vibration and
noise than conventional gears with straight teeth. Spiral bevel gears come in pairs and once damaged, they
should both be changed. Geometry and dimensions of considered spiral bevel pinion are shown in Fig. 1.
 The pinion shaft was a part of the first stage of the crane gearbox., with the engine power of 20 kW at 1200 rpm. Total
weight of the pinion shaft is 7.06 kg. Fig. 2 presents a close-up of the gear with damaged teeth. A damage pattern can
easily be detected with teeth gradually being brought to excessive contact and damage evolving over the gear. Little or no
corrosion occurred on the gear shaft.

 Material Chemical composition of the gear material was determined using glow discharge spectrometer (GDS) LECO
GDS500A, Tab. 1.
 SEM analysis- Fracture surfaces on the specimens cut from gears, Fig. 4, were examined using scanning electron
microscope(SEM) FEI Quanta 250 under suitable magnification. Spalling damage can be detected along the damage area.

 Discussion and conclusion: Visual examination of the failed spiral bevel gear damage evolving around gear teeth. This
damage was probably caused by the mismatch between the gear and the pinion designed axial lines causing unwanted
contact between the bodies. This contact resulted in raising the stress points along the gear teeth and excessive stress
gradually worn out the surface of the teeth. This tends to be the case of gear tooth spalling. Spallings are a product of
extremely high localized contact stresses that act as damage initiators and they tend to develop in the region near the pitch
circle of the tooth surface where the tooth pair is subjected to a higher mesh force.
3. Failure analysis of centrifugal pump impeller
Rui Yu, Jinxiang Liu⁎ School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China

 Abstract: This paper analyzed the looseness failure between impeller and shaft. In order to determine the cause of
the failure, the torque produced by external loads was calculated theoretically. The torque capacity of interference
connection was analyzed using finite element method (FEM). The basic mechanical properties of different impeller
were tested and applied to the FEM model to find out the influence of mechanical properties on interference
connection between impeller and shaft. The analysis results indicate that interference connection condition is
greatly affected by mechanical properties. The torque capacity of interference connection decreases with the
mechanical properties decrease. The maximum torque transmitted by interference connection being lower than
resultant resistance torque is the main reason of looseness failure between impeller and shaft.
 Introduction: Centrifugal pump is a key part of engine cooling system, taking away excess heat from engine to keep
engine working properly. If cooling pump fails during operation, the circulation of the coolant will be affected
directly, resulting in overheating failure of engine.
 Failure description of impeller: The centrifugal pumps served as cooling pumps are used in a heavy load diesel engine.
The impeller is made of cast iron ISO-200, and the shaft is made of 42CrMoA. The connection mode of impeller and
shaft is interference connection, keeping the torque transmission reliable. The speed of shaft is 5250 rpm, the lift of the
pump is 29 m, the volume flow rate is 800 L/min, the working medium is water with density of 1000 kg/m3 , and the
specific speed of the pump is 186. In the process of diesel engine test, several engines showed high temperature warning
of water temperature. By disassembling the pumps, the failures of pump are presented. Some of the interference
connections between impeller and pump shaft are loosen. There is friction and wear between impeller conical surface
and pump case during rated working condition due to axial force. However, the wear scar of impeller in circumferential
direction is particularly deep as shown in Fig. 1. Also there are some foreign metal bodies attached in the pump case, as
shown in Fig. 2.
 Material property experimental analysis:
 Microstructure examination: The specific crystal phase composition and graphite morphology were tested, as shown in
Table 1. The qualified impeller material contains 90% of the pearlite, whereas in the failure impeller material, there is
only 15% of pearlite. Fig. 3 shows the microstructure of impeller material, representing the qualified impeller and
failure impeller in Fig. 3(a) and (b), respectively.
 Failure reason analysis: The looseness of impeller and shaft interference connection is the result of competition of
torque capacity of interference connection and external resistance torque. When the resultant resistance torque is close
to the maximum torque interference connection can transmit, the failure of impeller looseness will occur.
 Conclusions: In this paper, the impeller looseness failure occurring in the pump rated working condition is analyzed. It
is clear that the degradation of the microstructure of failure impeller material will result in the decrease of mechanical
properties. The failure impeller material has lower elastic modulus and hardness, which directly lead to the reduction of
torque capacity of interference connection.
Thank you