Component engineering (MF2010)

Lecture 1 Course introduction Failure mechanisms

MF2010@md.kth.se http://www.kth.se/itm/inst/MMK/edu/inst_kurser/md/MF2010/
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Component engineering, 6 hp
Avanced level Compulsory for the specialization Machine Design Selectable fr M4,P4,T4 Component dimensioning Function, reliability, failure mechanisms Efficiency, Monte Carlo simulations, gear standard, FEM, modeling
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Atlas Copco Tools

- LTV angle nut runners

Atlas Copco Tools nut runner

motor motor planetary gears planetvxlar pinion pinionshaft axel exit shaft utgende axel

vinkelvxelhus bevel gear housing avstngningsventil closing valve

clutch koppling

Monte Carlo simulation

P W

Dimensioning of conical gears with the AGMA standard

Dimensioning of the pinion shaft

Modeling and simulation

Pitting

Yielding Flaking

Surface fatigue

Spalling Maximum shear stress

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Introduction 1 Reliability engineering 2 Failure modes of machine elements 3 Fatigue failure prediction and prevention

Vermelding onderdeel organisatie

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Failure analysis

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DN 13 sep 2007
Slitage orsak till SAS-haveri Slitage fick en bult att lossna. Det var orsaken till problemen med landningsstllet nr ett SAS-flygplan av modellen Dash-8 Q400 tvingades ndlanda i lborg i sndags, enligt en preliminr rapport frn den danska haverikommission, rapporterar nyhetsbyrn Ritzau.

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How to improve operating reliability?

The allowable pressure in sliding contacts between metals is limited by seizure

1) You need to know how stuff fails.

2) You need to know the measures Steel cast iron 510 MPa, that can be taken to prevent failures. In screw joints contact pressures
=0.120.18 up to 100 MPa are common, but Steelis- limited CuSnto or CuAl alloys 1020 the slidingmotion one single move.MPa, =0.120.18 Zinc plated to prevent
corrosion and seizure.

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How stuff fails How to prevent failure

Shear fracture Ductile fracture Fatigue fracture
Fatigue fracture
Check joint stiffness

Thread stripping
Check steel grade of the nut

Ductile fracture
Check preload

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Failure modes of machine elements

Yielding (Shear, ductile fraction by tension) Fatigue fracture (drive shaft, gear teeth) Wear (abrasive wear, adhesive, corrosion) Friction (jamming, stick-slip)
Wear mechanisms / failure analysis
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Fatigue failure

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Wear mechanisms

Dry sliding metal to metal contacts always show adhesive wear. Dry sliding polymer to metal contacts show abrasive wear.
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Zinc plated to prevent corrosion and seizure.

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Two body abrasive wear

Three body abrasive wear

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Adhesive wear (Galling)

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Wear mechanisms
Stainless steel bushing in contact with a polymer bearing has completely worn through in short time! Corrosion wear

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Wear mechanisms
Hertzian contact

Surface fatigue

Maximum shear stress

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Wear mechanisms
Adhesive scuffing, galling, cold welding, seizure, smearing Abrasive ploughing, polishing wear, grinding, scratching Corrosion thermo chemical wear, oxidative wear Surface fatigue pitting, spalling, flaking Motion related: fretting, false Brinelling

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How rolling bearings fail?

Flaking
Adhesive scuffing, galling, cold welding, seizure, smearing Abrasive ploughing, polishing wear, grinding, scratching Corrosion thermo chemical wear, oxidative wear Surface fatigue pitting, spalling, flaking Motion related: fretting, false Brinelling

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Failure mode classification for bearing damage

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How gears fail

Adhesive wear Surface fatigue Fatigue fracture Forced tooth breakage

Fatigue fracture

Forced tooth breakage

Pitting

Scuffing
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Angivna prestandabegrnsande fenomen r: Wear = ntning Scoring = repbildning Spalling = gropbildning eller ytutmattning Breakage = kuggbrott.

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How cams fail

Yielding Adhesive wear Surface fatigue Abrasive wear
Galling

Yielding

Pitting

Spalling

Spalling

Mild abrasive wear

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How journal bearings fail

Scuffing

Adhesive scuffing, galling, cold welding, seizure, smearing Abrasive ploughing, polishing wear, grinding, scratching Corrosion thermo chemical wear, oxidative wear Surface fatigue pitting, spalling, flaking Motion related: fretting, false Brinelling

Scuffing

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How journal bearings fail

Fatigue fractured Crankshaft

Fatigue fractured surface with band shaped progression marks

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How shaft-hub connections fail

Fatigue fracture

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How transmission chains fail

Fatigue fracture Abrasive wear Fatigue fracture formed without deformation Corrosive wear Yielding Fatigue fracture Yielding

Abrasive wear

Corrosion

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How rail-wheel systems fail

Abrasive wear Adhesive wear Fatigue fracture Yielding

Yielding

Fracture initiated by surface fatigue

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Friction determines the life of clutches

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Friction change with running time

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Failure modes of machine elements

Summary
About 80% of all machine failures are of Tribology nature Adhesive wear, abrasive wear corrosion wear Fatigue wear Variation in friction result in unpredictable preload Stick slip may cause uncontrolled motion, noise Radial play caused high cyclic loading Design for lifetime performance and reliability
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