DJJ50203

TROUBLESHOOTING
& MAINTENANCE
FOR MECHANICAL
COMPONENTS
[CASE STUDY]
LECTURER: DR. MOHD ELIAS BIN DAUD
 NAME NO.MATRICS
MUHAMMAD JAFRI HASYIM 08DKM19F1111
BIN MOHD SHAH
MUHAMMAD YUSUF BIN 08DKM19F1118
ZULKEFLI
MUHAMMAD ILHAM BIN 08DKM19F1119
ISMAIL
MUHAMMAD ARIEF BIN MOHD 08DKM19F1139
HISHAMUDIN
EXPLAIN THE
TYPE FAILURE
OF DRIVE AND
CAUSED OF THE
FAILURE.
TYPE OF FAILURE FOR CHAIN
OVERLOAD
Chain subjected to an enormous one-time load, resulting in irreversible material
deformation and a very short chain life.

FATIGUE
Chain that has been subjected to repeated high loads above its endurance limit, causing
it to fracture.

WEAR
The typical load between the pin and the bush eventually wears away the material,
stretching the chain past its useable limit. The majority of chains are made to break due
to wear.
CAUSE OF THE FAILURE
01
IMPROPER SELECTION
The product selection stage, as with many
mechanical and engineering components, is
the first point at which an ill-advised or
erroneous option can cause a chain drive to
experience a lifetime of problems,
culminating in early failure.
03
IMPROPER LUBRICATION
The most common cause of premature chain
breakdown is insufficient lubrication.
Lubricant selection is critical for ensuring
that roller chain is properly lubricated using
a substance that allows for effective
operation while also protecting it from
impurities such as moisture.
02
IMPROPER INSTALLATION
Following the acquisition of the proper
product, the installation stage is the next
step in the process where businesses can
assist in preventing premature transmission
chain failure.
04
IMPROPER MAINTENANCE
Effective inspection and maintenance
methods are critical for guaranteeing the
efficient operation of all mechanical
components and extending their service life,
and chain is no exception.
EXPLAIN HOW GEAR
IS MAINTAINED BY
REFERRED TO THE
RECOMMENDATION
MANUFACTURER.

PERFORM THE GEAR

MAINTENANCE PROCEDURE
THE GEAR MAINTENANCE PROCEDURE
1) 2)

Visually examine gearboxes on a regular Gearboxes are frequently required to work

basis. Look for oil leaks on the input and in filthy, dusty conditions. Keep them as
output shafts, as well as paint clean as possible to prevent contaminants
discoloration, which could indicate from entering the unit and to facilitate
overheating. visual examinations.

3)

Routine lubrication in accordance with the manufacturer’s

specifications isessential. Make sure you’re using the right
lubricant with the correct additives for your application
and consult the manufacturer or your distributor if there is
any ambiguity.
4) 5)

With an infrared gun, monitor the Regular vibration analysis is especially

gearbox temperature and notice
any rapid fluctuations that will
almost probably indicate a
problem.
crucial in a noisy atmosphere where it could
go unnoticed. Keep an eye on the bearings
and internal gears for vibration. An increase
in vibration is a solid sign that trouble is on
the way.

6)

Remove the inspection covers and look for

evidence of pitting or spiralling on the internal
gears. Check the contact pattern of the gear
teeth with engineers' blue. Wearing bearings or
housings would cause misalignment.
7)
Check that the breathers are of the
correct type and that they are kept
as clean and free of debris as
feasible at all times. This is more
challenging in unclean applications
like brick production or cement
manufacturing, but it just
emphasises the importance of
excellent housekeeping.
8)
A dial indicator can be used to
check backlash and endplay. An
increase in backlash would indicate
gear tooth wear, while an increase
in endplay would indicate bearing
or housing wear.
9)
It's likely that the gearbox's
requirements have changed since it
was first specified. Examine the
gearbox's specifications and power
input to check that it is operating
within the manufacturer's
requirements.
10)
Cooperate with a manufacturer or a reputable
distributor who can provide comprehensive
gearbox servicing, refurbishing, and
replacement services. It is feasible to almost
eliminate unexpected downtime and greatly
cut maintenance expenses by collaborating
with specialists and implementing an effective
gearbox maintenance programme.
 WHAT ARE ROOT
CAUSE OF THE
BEARING FAILURE
IN THE INDUSTRY
APPLICATION?

PERFORM BEARING FAILURE ARE REFER TO

ANBNORMAL BEARING TEMPERATURE,
NOISES OF ROTATING BEARING, AND
VIBRATION OF ROTATING BEARING.
ABNORMAL BEARING
TEMPERATURE
A high bearing temperature could be a sign
of a defective lubrication system. Depending
on bearing size and speed, as well as
surrounding conditions, normal temperature
can range from "cold to warm to the touch"
to "too hot to touch for more than a few
seconds." There is too much grease if the
temperature is very high and there is
considerable grease leaking. A high
temperature combined with little grease at
the seals, especially if the bearing is loud,
usually indicates a lack of grease. Proper
lubrication is indicated by a normal
temperature and a light appearance of grease
at the seals.
NOISES OF ROTATING
BEARING
While an imperfection, such as a dent or
corrosion, is present on a rolling bearing's
completed raceways surface, a pulsing,
machine-gun-like noise is produced when the
bearing spins. Fault noise is the result of the
rolling elements colliding with a flaw on the
raceway surface.

So, rust preventative oil, coatings, cleaners

for rust prevention oil and water-based rust
preventive, de-watering rust preventive, and
so on are solutions for rust prevention and
cleaning. Rust prevention procedures are
taken based on the needs of the individual.
VIBRATION OF ROTATING
BEARING

Summary Rolling bearing vibration can

be complicated, and it can be caused by
geometrical flaws in the manufacturing
process, faults on the rolling surfaces, or
geometrical mistakes in linked
components.
HOW IS
BEARING
MAINTAINED
BY
REFERRED
TO THE
RECOMMEND
MANUFACTU
RER.
Use caution when handling
-Bearing are sensitive materials and should never be removed from their container until
they are ready to be used.
-Never pound, hammer, or apply direct force to it or its outer ring, as this might destroy
the rolling parts and create misalignment.
-Avoid exposing them to any impurities in the air, since even a speck of dirt might cause
early failure.
Make that the bearing housing and shaft are in good shape.
-When a bearing is used for mounting, it is critical to inspect the housing and shaft for
any physical damage or condition.
-Wipe the surfaces clean with a soft cloth and make sure any nicks or burrs are gone.
Always make use of the appropriate tools.
-In the mounting and dismounting process, specialised instruments such as bearing
pullers, bearing fitting tool kits, oil injector kits, hydraulic nuts, or induction warmers
should be utilised.-These tools make mounting and dismounting as easy as possible,
reducing the danger of harm.
REFERENCE

https://www.google.com/url?sa=t&source=web&rct=j&url=https://www.renold.com/media/291236/trc
_module_3.pdf&ved=2ahUKEwi0i6bM8aX1AhWRTmwGHTcEDAgQFnoECBIQAQ&usg=AOvVaw
3GZXBgJQ8StLDFlCAYLuRi

https://www.google.com/url?sa=t&source=web&rct=j&url=https://www.hayley-group.co.uk/2021/06/0
2/the-4-chief-causes-of-transmission-chain-failure-and-how-to-combatthem/&ved=2ahUKEwjXpcOK
8qX1AhV5RWwGHZRmBmsQFnoECEUQBQ&usg=AOvVaw0t1_Szw2CcvYVdMVcpm5ps

https://www.google.com/url?sa=t&source=web&rct=j&url=https://www.renold.com/blog/10-simple-st
eps-to-best-practice-in-gearboxmaintenance&ved=2ahUKEwiB6r2H96X1AhWJUGwGHQ2EBe8QFn
oECAQQAQ&usg=AOvVaw2UTLrcddd9OmQ7RqpENh7p

https://www.researchgate.net/publication/242663970_An_Overview_of_Bearing_Vibration_Analysis#:
~:text=In%20simple%20cases%2C%20the%20vibration%20behavior%20of%20rolling,process%2C%
20component%20instability%20as%20well%20as%20defect%20itself