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The horizontal cross-travel shaft on a derrick failed after two years of service. The shaft was required to be made of 4140 steel quenched to a hardness of 302 to 352 HRB. The shaft was found to have fractured approximately 13 mm from the change in section between the splined end and the shaft proper. The cracks were found to have propagated in the longitudinal and transverse directions until failures occurred. It was showed by a transverse section through the spline that the longitudinal cracks were initiated at the sharp corners at the roots of the spline teeth. The...

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