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Published: 30 August 2021
Fig. 4 Micrographs of cracks after heat treatment caused either by sharp radii or related machining problems. (a) 4140 steel as-quenched and tempered; microstructure is tempered martensite with quench crack at area of dimensional change. 2% nital etch. Original magnification: 100×. (b) 4142H More
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Published: 30 August 2021
Fig. 21 Graph of stress-concentration effects of different fillet radii on the stress-intensity factor, K More
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Published: 30 August 2021
Fig. 65 Incorrect and correct shaft-shoulder heights and fillet radii for mounting rolling-element bearings on shafts. (a, b, c) Incorrect designs. (d) Correct design More
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.machtools.c9001155
EISBN: 978-1-62708-223-5
... fractures. The appearance of the fracture in the arbors indicated ductile fatigue fracture which had its origin in the radii between groove and flange. These radii of 0.15 and 0.2 mm were too small for the load on the milling machine. In addition there were grooves at the base of the radii which had...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.design.c0047100
EISBN: 978-1-62708-233-4
... the fractures were fatigue-induced failures due to sharp radii in the fillets. The stress-concentrating effects of the fillets caused fatigue cracks to initiate and grow under cyclic loading until the crack depth was critical, causing the shaft to fail and rendering the assembly inoperative. Recommendations...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.homegoods.c0091857
EISBN: 978-1-62708-222-8
... of the assembly and the bends at the bottom shoulders of the two mixer arms. Multiple fatigue crack origins on the inside radii of the bends at the bottom shoulders was revealed by analysis of the failed mixer blades. It was revealed by metallographic examination that the shoulders on the arms were cold bent...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c9001529
EISBN: 978-1-62708-217-4
... to a 0.25-in. (6.4-mm) radii around the affected rivets. The repair process involved removal of the locally-affected material and addition of a skin doubler to restore the aircraft structure to the originally designed condition. Damage features are described briefly. Aircraft components Lightning...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c9001733
EISBN: 978-1-62708-225-9
... alternating stress, and buckling (compressive) cyclic loading. The mode of failure was found to be reversed bending fatigue caused by drive cables moving over guide pulleys of small radii. Modifications of the machinery and drive cable system were suggested. Bending fatigue Drive cables Rubber...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.matlhand.c0048073
EISBN: 978-1-62708-224-2
... Abstract A drum pinion shaft (1030 steel) which was part of the hoisting gear of a crane (capacity 18,140-kg) operating in a blooming mill failed while lifting a 9070 kg load. Chatter marks, rough-machining marks, and sharp corner radii were revealed in the keyway which extended into a shoulder...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.design.c0047234
EISBN: 978-1-62708-233-4
.... Recommendations included that the radii be increased at the sharp corners and that lock-wiring be used to secure against bolt loosening. Bolted joints Deburring Drums (containers) Stress concentration Fe-2.79C-25.2Cr Fatigue fracture Deburring drums are filled with abrasive, water, and small parts...
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Published: 30 August 2021
Fig. 11 Crankshaft that fractured through the web between a main journal and a pin journal. (a) Photograph of fracture location. Beach marks and ratchet marks indicative of fatigue fracture were observed, with likely origins at the main (top) and pin journal (bottom) radii. (b) Fine, parallel More
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Published: 01 December 2019
Fig. 6 Results of rolling contact fatigue test: ( a ) varies of friction coefficient with the test time,; and ( b ) FWHM along the radii of test samples) More
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Published: 01 December 2019
Fig. 9 Comparison of cross sections of the Design 1 and 6 drive shafts. The areas marked with circles are of particular concern because they differ in terms of fillet radii and cross-sectional area. More
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Published: 30 August 2021
Fig. 32 Typical design of a 45,360 kg (50 ton) capacity grade 1020 steel C-hook with a stress-relief groove at end of threads and well-proportioned radii. Dimensions given in inches More
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.matlhand.c0048020
EISBN: 978-1-62708-224-2
... used smaller sheaves caused excessive bending stresses in the rope. The 18 x 7 rope was replaced by two 6 x 37 side-by-side counter-stranded steel-core ropes as a corrective measure. Radii Sheaves Fe-0.53C Fatigue fracture A 13-mm ( 1 2 -in.) diam 18 × 7 fiber-core improved plow...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.design.c0047414
EISBN: 978-1-62708-233-4
...). This fatigue failure was the result of poor design, which incorporated a notch that acted as a stress raiser, leading to fatigue-crack growth. A generous radius was recommended to avoid similar failures. Radii Stress concentration Steel casting Fatigue fracture Figure 1 shows a fracture...
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Published: 01 January 2002
Fig. 33 Effect of stress raisers on stress concentration and distribution of stress at several changes of form in components. (a) to (c) Progressive increases in stress with decreasing fillet radii. (d) to (f) Relative magnitude and distribution of stress resulting from uniform loading. (g More
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0048150
EISBN: 978-1-62708-235-8
... in the spring (caused by the very small inside radius). The corner radius was increased to 0.76 mm and the tools were re-polished to avoid tool marks. Cams Radii Stampings Fe-0.75C Fatigue fracture Parts such as the one shown in Fig. 1(a) were used as grease-wiper springs for cams. The springs...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.matlhand.c9001461
EISBN: 978-1-62708-224-2
... of section where the shank joined the hook portion. To minimize the possibility of fatigue cracking, it was recommended that a generous radius be provided at the change of section. Cranes Radii Low-carbon steel Brittle fracture M This hook, which was marked for a safe working load of 2 tons...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.usage.c0047823
EISBN: 978-1-62708-236-5
... stresses were caused by misalignment between the electric motor and compressor and were transmitted to the shaft through the geared coupling. Flexible-disk couplings capable of transmitting the required horsepower were installed on the shafts as a corrective measure. Alignment Bending Radii 4340...