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M.A. Hili, T. Fakhfakh, M. Haddar
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N. Ejaz, I. Salam, A. Tauqir
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Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047986
EISBN: 978-1-62708-217-4
..., with more damage on one of the shoulders of the groove, was revealed during examination of the outer raceway of the bearing which indicated misalignment of the bearing. No damage other than spalling cavities in the inner-ring raceway, caused by the elongated subsurface inclusion revealed by metallographic...
Abstract
The engine on a jet aircraft was shut down immediately as it produced excessive vibration. Complete failure of the cage in one of the two main-shaft ball bearings (placed side by side in the engine) was revealed in the dismantled engine. The ball bearings (made of vacuum-melted 52100 steel) were both of the single-row deep-groove type with split inner rings and were designed to operate at a maximum temperature of 175 deg C. Overtempering of the rings was indicated by the reduced hardness in comparison to unfailed rings. Severe damage to approximately 20% of the load-bearing surface, with more damage on one of the shoulders of the groove, was revealed during examination of the outer raceway of the bearing which indicated misalignment of the bearing. No damage other than spalling cavities in the inner-ring raceway, caused by the elongated subsurface inclusion revealed by metallographic examination of circumferential section of the largest cavity, was exhibited by the second bearing. It was concluded that the fracture of the cage was caused by overheating and misalignment caused excessive stressing of the bearing on the main shaft.
Book Chapter
Fatigue Failure of a Carburized Steel Bevel Pinion Because of Misalignment
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0048273
EISBN: 978-1-62708-225-9
... failed by tooth-bending fatigue. Spalling was also noted on the pressure (drive) side of each tooth at the toe end which indicated some mechanical misalignment of the pinion with the mating gear that caused the cyclic shock load to be applied to the toe ends of the teeth. Cyclic loads Gear teeth...
Abstract
Several teeth of a bevel pinion which was part of a drive unit in an edging mill failed after three months in service. Specifications required that the pinion be made from a 2317 steel forging and that the teeth be carburized and hardened to a case hardness of 56 HRC and a core hardness of 250 HRB. Two teeth were revealed by visual examination to have broken at the root and fatigue marks extending across almost the entire tooth were exhibited by the surface of the fracture. Cracking in all the tooth was showed by magnetic-particle inspection. The pinion was concluded to have failed by tooth-bending fatigue. Spalling was also noted on the pressure (drive) side of each tooth at the toe end which indicated some mechanical misalignment of the pinion with the mating gear that caused the cyclic shock load to be applied to the toe ends of the teeth.
Book Chapter
Brittle Fracture of a Gray Iron Nut Due to Overload Caused by Misalignment in Assembly
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0047315
EISBN: 978-1-62708-225-9
... the conclusions that brittle fracture of the flange from the body was the result of overload caused by misalignment between the flange and the roll holder. The microstructure contained graphite flakes of excessive size and inclusions in critical areas; however, these metallurgical imperfections did not appear...
Abstract
A sand-cast gray iron flanged nut was used to adjust the upper roll on a 3.05 m (10 ft) pyramid-type plate-bending machine. The flange broke away from the body of the nut during service. Analysis (visual inspection and 150x micrographs of sections etched with nital) supported the conclusions that brittle fracture of the flange from the body was the result of overload caused by misalignment between the flange and the roll holder. The microstructure contained graphite flakes of excessive size and inclusions in critical areas; however, these metallurgical imperfections did not appear to have had significant effects on the fracture. Recommendations included carefully and properly aligning the flange surface with the roll holder to achieve uniform distribution of the load. Also, a more ductile metal, such as steel or ductile iron, would be more suitable for this application and would require less exact alignment.
Image
Diesel-engine crankshaft that broke because of misalignment. (a) Fatigue ma...
Available to PurchasePublished: 01 January 2002
Fig. 21 Diesel-engine crankshaft that broke because of misalignment. (a) Fatigue marks on the fracture surface. (b) Micrograph of a section through the fracture origin showing a small crack (arrow) and some inclusions. Etched with nital. 500×
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Image
Published: 01 January 2002
Fig. 27 Four types of misalignment of rolling-element bearings.
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Two failure cases showing the effect of misalignment or tilting moments on ...
Available to Purchase
in Failures of Rolling-Element Bearings and Their Prevention
> Analysis and Prevention of Component and Equipment Failures
Published: 30 August 2021
Fig. 29 Two failure cases showing the effect of misalignment or tilting moments on rolling-element bearings. (a) Deep-groove ball bearing with rotating outer ring. (b) Tapered roller bearing with rotating outer ring. Source: Ref 24
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Image
Four types of potential misalignment problems of rolling-element bearing ar...
Available to Purchase
in Failures of Rolling-Element Bearings and Their Prevention
> Analysis and Prevention of Component and Equipment Failures
Published: 30 August 2021
Fig. 66 Four types of potential misalignment problems of rolling-element bearing arrangements
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Image
in Failure Analysis of Gears and Reducers
> Analysis and Prevention of Component and Equipment Failures
Published: 30 August 2021
Fig. 13 Idealized effect of misalignment on the bending and contact tooth stress
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Image
Angular misalignment (peaking) in a cylindrical shell longitudinal weld and...
Available to PurchasePublished: 30 August 2021
Fig. 33 Angular misalignment (peaking) in a cylindrical shell longitudinal weld and spherical shell weld. Adapted from API 579 ( Ref 16 )
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Image
Holes enlarged by torch cutting to accommodate beam misalignment in constru...
Available to Purchase
in Failure Analysis of a Collapsed Roof
> ASM Failure Analysis Case Histories: Buildings, Bridges, and Infrastructure
Published: 01 June 2019
Fig. 5 Holes enlarged by torch cutting to accommodate beam misalignment in construction.
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Image
Section of longitudinal weld. Edge misalignment. Etch: oxalic acid 10%. 10 ...
Available to Purchase
in Intercrystalline Corrosion of Welded Stainless Steel Pipelines in Marine Environment
> ASM Failure Analysis Case Histories: Buildings, Bridges, and Infrastructure
Published: 01 June 2019
Fig. 9 Section of longitudinal weld. Edge misalignment. Etch: oxalic acid 10%. 10 ×
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Book Chapter
Failure Analysis of a Misaligned and Unbalanced Flexible Rotor
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001851
EISBN: 978-1-62708-241-9
... Abstract Shaft misalignment and rotor unbalance contribute to the premature failure of many machine components. To understand how these failures occur and quantify the effects, investigators developed a model of a rotating assembly, including a motor, flexible coupling, driveshaft, and bearings...
Abstract
Shaft misalignment and rotor unbalance contribute to the premature failure of many machine components. To understand how these failures occur and quantify the effects, investigators developed a model of a rotating assembly, including a motor, flexible coupling, driveshaft, and bearings. Equations of motion accounting for misalignment and unbalance were then derived using finite elements. A spectral method for resolving these equations was also developed, making it possible to obtain and analyze dynamic system response and identify misalignment and unbalance conditions.
Image
Erosion damage and misaligned bore of the AISI H13 tool steel zinc die-cast...
Available to PurchasePublished: 01 January 2002
Fig. 50(b) Erosion damage and misaligned bore of the AISI H13 tool steel zinc die-casting nozzle shown in Fig. 50(a) after longitudinal splitting. Actual size
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Erosion damage and misaligned bore of the AISI H13 tool steel zinc die cast...
Available to PurchasePublished: 01 January 2002
Fig. 28 Erosion damage and misaligned bore of the AISI H13 tool steel zinc die casting nozzle shown in Fig. 27 after longitudinal splitting. Actual size
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in Failure Analysis of Gears and Reducers
> Analysis and Prevention of Component and Equipment Failures
Published: 30 August 2021
Fig. 39 Misaligned cast steel bevel gear tooth
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in Failure Analysis of a Misaligned and Unbalanced Flexible Rotor
> Handbook of Case Histories in Failure Analysis
Published: 01 December 2019
Fig. 2 Misaligned spinning system
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Book Chapter
Failure Analysis of an Aero Engine Ball Bearing
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001755
EISBN: 978-1-62708-241-9
... Abstract An aero engine failed due to the misalignment of the ball bearing fitted on the main shaft of the engine. The aero engine incorporates two independent compressors: a six-stage axial flow LP compressor and a nine-stage axial flow HP compressor. The bearing under consideration is a HP...
Abstract
An aero engine failed due to the misalignment of the ball bearing fitted on the main shaft of the engine. The aero engine incorporates two independent compressors: a six-stage axial flow LP compressor and a nine-stage axial flow HP compressor. The bearing under consideration is a HP location bearing and is fitted at the rear of the nine-stage compressor. It was supposed to operate for at least 5000 h, but failed catastrophically after 1300 h, rendering the engine unserviceable. Unusually high stresses caused by misalignment and uneven axial loading resulted in the generation of fatigue crack(s) in the inner race. When the crack reached the critical size, the collar of the race fractured, causing subsequent damage. The cage also failed due to excessive stresses in the axial direction, and its material was smeared on the steel balls and the outer race.
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