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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.conag.c9001495
EISBN: 978-1-62708-221-1
... and thus met material specification. The failure was a result of torsional fatigue in the tensile plane, originating from one of several gouges around the splined radius of the shaft. The fatigue crack progressed for a large number of cycles before final fracture. The shaft met metallurgical requirements...
Abstract
An axle shaft in an open-pit mining truck hauling overburden failed after operating for 27,000 h. Previous failures had resulted from longitudinal shear, but this had not, bringing material quality into question. Chemical analysis verified that the part was SAE4340 Ni-Cr-Mo alloy steel and thus met material specification. The failure was a result of torsional fatigue in the tensile plane, originating from one of several gouges around the splined radius of the shaft. The fatigue crack progressed for a large number of cycles before final fracture. The shaft met metallurgical requirements and should have withstood normal operating conditions. The spacing of the gouge marks coincided with the spacing of the splines, indicative of careless assembly with the mating wheel gear.
Book Chapter
Torsional Fatigue Failure of Crane Shaft
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.conag.c9001468
EISBN: 978-1-62708-221-1
... Abstract In a shaft subjected to reversed torsional stresses, failure resulted from the gradual development of fatigue cracks from opposite sides of the shaft. These broke out from origins located adjacent to the fillets at the start of the square section. The remaining uncracked material which...
Abstract
In a shaft subjected to reversed torsional stresses, failure resulted from the gradual development of fatigue cracks from opposite sides of the shaft. These broke out from origins located adjacent to the fillets at the start of the square section. The remaining uncracked material which fractured at the time of the mishap was in the form of a narrow strip, situated slightly to one side of the center of the shaft. The material was a mild steel in the normalized or annealed condition, having a carbon content of approximately 0.3%. The cracking was characteristic of that resulting from torsional fatigue. Because it occurred on two different planes at 45 deg to the axis of the shaft it was due to reversals of torsional stress rather than fluctuations of unidirectional torque. Following this failure, the shafts of six other similar cranes were tested ultrasonically. Cracks to varying degree were found in all the shafts. Timely replacement was possible and the likelihood of serious accidents removed.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c0091096
EISBN: 978-1-62708-234-1
... the conclusion that the basic failure mechanism was fracture by torsional fatigue, which started at numerous surface shear cracks, both longitudinal and transverse, that developed in the periphery of the root of the shear groove. These shear cracks resulted from high peak loads caused by chatter. The shear...
Abstract
A 4340 steel shaft, the driving member of a large rotor subject to cyclic loading and frequent overloads, broke after three weeks of operation. The driving shaft contained a shear groove at which the shaft should break if a sudden high overload occurred, thus preventing damage to an expensive gear mechanism. The rotor was subjected to severe chatter, which was an abnormal condition resulting from a series of continuous small overloads occurring at a frequency of around three per second. Investigation (visual inspection, hardness testing, and hot acid etch images) supported the conclusion that the basic failure mechanism was fracture by torsional fatigue, which started at numerous surface shear cracks, both longitudinal and transverse, that developed in the periphery of the root of the shear groove. These shear cracks resulted from high peak loads caused by chatter. The shear groove in the shaft had performed its function, but at a lower overload level than intended. Recommendations included increasing the fatigue strength of the shaft by shot peening the shear groove to minimize chatter.
Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001764
EISBN: 978-1-62708-241-9
.... All of the failures, a total of 14, were of the same type of design, which according to finite-element analysis, produces a significantly higher level of stress. SEM examination of the fracture surface of one of the failed drive shafts revealed fatigue striations near the OD and ductile dimpling near...
Abstract
High failure rates in the drive shafts of 40 newly acquired articulated buses was investigated. The drive shafts were fabricated from a low-carbon (0.45%) steel similar to AISI 5046. Investigators examined all 40 buses, discovering six different drive shaft designs across the fleet. All of the failures, a total of 14, were of the same type of design, which according to finite-element analysis, produces a significantly higher level of stress. SEM examination of the fracture surface of one of the failed drive shafts revealed fatigue striations near the OD and ductile dimpling near the ID, evidence of high-cycle fatigue. Based on the failure rate and fatigue life predictions, it was recommended to discontinue the use of drive shafts with the inferior design.
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4340 steel rotor shaft that failed by torsional fatigue. (a) Shear groove d...
Available to PurchasePublished: 01 January 2002
Fig. 7 4340 steel rotor shaft that failed by torsional fatigue. (a) Shear groove designed to protect gear mechanism from sudden overload. Dimensions are in inches. (b) Star-shaped pattern on a fracture surface of the shaft. (c) Longitudinal and transverse shear cracks on the surface
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Stress fields and corresponding torsional-fatigue cracks. (a) and (b) Shaft...
Available to PurchasePublished: 01 January 2002
Fig. 15 Stress fields and corresponding torsional-fatigue cracks. (a) and (b) Shaft with keyway. (c) Shaft with splines
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Torsional fatigue failure of boron-containing alloy steel helical spring. F...
Available to PurchasePublished: 01 January 2002
Fig. 17 Torsional fatigue failure of boron-containing alloy steel helical spring. Fatigue initiated at an abraded area marked by arrows. The material in compression coil springs is subjected to unidirectional torsion, so fatigue propagates on a single helical surface. Source: Ref 4
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Surface of a torsional-fatigue fracture in an induction-hardened 1041 (1541...
Available to PurchasePublished: 01 January 2002
Fig. 19 Surface of a torsional-fatigue fracture in an induction-hardened 1041 (1541) steel shaft. The shaft fractured after 450 hours of endurance testing. 1 1 4 ×
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Schematic of the initiation of torsional-fatigue cracks in shaft subjected ...
Available to PurchasePublished: 01 January 2002
Fig. 30 Schematic of the initiation of torsional-fatigue cracks in shaft subjected to longitudinal shear (a) or transverse shear (b). Dashed lines indicate other cracks that can appear when torsional stresses are reversed.
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Fracture surfaces of a torsional fatigue-test specimen. Courtesy of Greg Fe...
Available to PurchasePublished: 01 January 2002
Fig. 31 Fracture surfaces of a torsional fatigue-test specimen. Courtesy of Greg Fett, Dana Corporation
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Image
4340 steel rotor shaft that failed by torsional fatigue. (a) Shear groove d...
Available to PurchasePublished: 01 January 2002
Fig. 32 4340 steel rotor shaft that failed by torsional fatigue. (a) Shear groove designed to protect gear mechanism from sudden overload. Dimensions are in inches. (b) Star-shaped pattern on a fracture surface of the shaft. (c) Longitudinal and transverse shear cracks on the surface
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Image
Torsional fatigue failure of boron-containing alloy steel helical spring. F...
Available to PurchasePublished: 15 January 2021
Fig. 17 Torsional fatigue failure of boron-containing alloy steel helical spring. Fatigue initiated at an abraded area marked by arrows. The material in compression coil springs is subjected to unidirectional torsion, so fatigue propagates on a single helical surface. Source: Ref 4
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Image
Surface of a torsional fatigue fracture in an induction-hardened 1041 (1541...
Available to PurchasePublished: 15 January 2021
Fig. 28 Surface of a torsional fatigue fracture in an induction-hardened 1041 (1541) steel shaft, which fractured after 450 h of endurance testing
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Image
Schematic of the initiation of torsional fatigue cracks in a shaft subjecte...
Available to PurchasePublished: 15 January 2021
Fig. 39 Schematic of the initiation of torsional fatigue cracks in a shaft subjected to (a) longitudinal shear and (b) transverse shear. Dashed lines indicate other cracks that can appear when torsional stresses are reversed.
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Image
Fracture surfaces of a torsional fatigue test specimen. Courtesy of G. Fett...
Available to PurchasePublished: 15 January 2021
Fig. 40 Fracture surfaces of a torsional fatigue test specimen. Courtesy of G. Fett, Dana Corporation
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Image
4340 steel rotor shaft that failed by torsional fatigue. (a) Shear groove d...
Available to PurchasePublished: 15 January 2021
Fig. 41 4340 steel rotor shaft that failed by torsional fatigue. (a) Shear groove designed to protect gear mechanism from sudden overload (dimensions are in inches). (b) Star-shaped pattern on a fracture surface of the shaft. (c) Longitudinal and transverse shear cracks on the surface
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Image
Failure of this axle shaft resulted from torsional fatigue in the tensile p...
Available to Purchase
in Torsional Fatigue Failure of an Axle Shaft
> ASM Failure Analysis Case Histories: Construction, Mining, and Agricultural Equipment
Published: 01 June 2019
Fig. 1 Failure of this axle shaft resulted from torsional fatigue in the tensile plane, originating from one of several gouge marks observed around the shaft at the splined radius. The fatigue crack progressed for a large number of cycles before final fracture.
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Image
in Torsional Fatigue Failure of Crane Shaft
> ASM Failure Analysis Case Histories: Construction, Mining, and Agricultural Equipment
Published: 01 June 2019
Image
Grade 4340 steel rotor shaft that failed by torsional fatigue. (a) Shear gr...
Available to PurchasePublished: 30 August 2021
Fig. 7 Grade 4340 steel rotor shaft that failed by torsional fatigue. (a) Shear groove designed to protect gear mechanism from sudden overload. Dimensions are in inches. (b) Star-shaped pattern on a fracture surface of the shaft. (c) Longitudinal and transverse shear cracks on the surface
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Image
Stress fields and corresponding torsional-fatigue cracks. (a) and (b) Shaft...
Available to PurchasePublished: 30 August 2021
Fig. 27 Stress fields and corresponding torsional-fatigue cracks. (a) and (b) Shaft with keyway. (c) Shaft with splines
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