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stress concentration
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Book Chapter
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
... calculations to be very close to the maximum allowable fluctuating stress for the material. The wiper springs were concluded to be fractured in fatigue and the cyclic loading resulted from cam rotation. The maximum applied stress approached the allowable limit due to high stress-concentration factor...
Abstract
Grease-wiper springs for cams formed from stampings of 0.25-mm thick carbon spring steel (0.65 to 0.80% C) fractured at the 0.025 mm radius on the stamped 135 deg corner at a 90 deg bend after 5,000,000 cycles. Tool marks 2 to 2.3 mm from the center of the stamped bend were disclosed by visual examination. Fatigue striations originating from cracks at the 0.025 mm radius inside corner at the bend were revealed by SEM of the fractured surface. The maximum stress at the bend, in stock of maximum thickness and as a function of the radius of the 135 deg corner, was indicated by stress calculations to be very close to the maximum allowable fluctuating stress for the material. The wiper springs were concluded to be fractured in fatigue and the cyclic loading resulted from cam rotation. The maximum applied stress approached the allowable limit due to high stress-concentration factor 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.
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
... this fracture-initiation area showed fatigue striations. No casting or metallurgical structural defects were found that could explain the failures. This evidence supports the conclusion that cracking was a result of the stress-concentration site at the bolt holes where a fatigue-initiated fracture occurred...
Abstract
Several deburring drums that fractured were filled with abrasive, water, and small parts, such as roller bearing rollers, and rotated on their axis at 36 rpm. Cracks were discovered very early in the service lives of these high-chromium white iron cast structures. All of the fractures were through bolt holes in the mounting flange. The holes had a sharp edge and exhibited uneven wear on the inside diameter. In operation, the mounting bolts were frequently found to be loose and in at least one case broken off. A 25x scanning electron microscopy (SEM) fractograph from near this fracture-initiation area showed fatigue striations. No casting or metallurgical structural defects were found that could explain the failures. This evidence supports the conclusion that cracking was a result of the stress-concentration site at the bolt holes where a fatigue-initiated fracture occurred. Recommendations included that the radii be increased at the sharp corners and that lock-wiring be used to secure against bolt loosening.
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Published: 01 January 2002
Fig. 17 Stress concentration at eyebolt. k t , stress concentration factor; σ a , nominal (average) stress
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Published: 15 January 2021
Fig. 17 Stress concentration at eyebolt. k t , stress-concentration factor; σ a , nominal (average) stress
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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
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Image
Published: 15 January 2021
Fig. 42 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
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Published: 01 January 2002
Fig. 10 Effect of size of fillet radius on stress concentration at a change in shaft diameter. See text for discussion.
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in X-Ray Diffraction Residual Stress Measurement in Failure Analysis
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 30 Finite-element model showing maximum stress concentration in cloverleaf radius. The highest stress concentration is in the small black area surrounded by white.
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in Failure of Shaft from an Electic Goods Lift
> ASM Failure Analysis Case Histories: Material Handling Equipment
Published: 01 June 2019
Fig. 3 Various methods of reducing stress concentration at shoulder required for locating bearing races, etc.
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Published: 30 August 2021
Fig. 20 Effect of size of fillet radius on stress concentration at a change in shaft diameter. See text for discussion
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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
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in Redesign of a Forged Manual Gear-Shift Lever Mechanism to Overcome Unacceptable Fatigue Failure of Original Forging
> ASM Failure Analysis Case Histories: Automobiles and Trucks
Published: 01 June 2019
Fig. 2 Stress concentration factor obtained in bending a quenched and tempered steel shaft having a circular fillet
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in Use of XRD to Evaluate Cracks in Steel Cargo Tiedown Sockets
> ASM Failure Analysis Case Histories: Offshore, Shipbuilding, and Marine Equipment
Published: 01 June 2019
Fig. 1 Finite-element model showing maximum stress concentration in cloverleaf radius. The highest stress concentration is in the small black area surrounded by white.
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in X-Ray Diffraction Residual-Stress Measurement in Failure Analysis
> Failure Analysis and Prevention
Published: 15 January 2021
Fig. 30 Finite-element model showing maximum stress concentration in cloverleaf radius. The highest stress concentration is in the small black area surrounded by white.
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in Failure Analysis of Gas Turbine Last Stage Bucket Made of Udimet 500 Superalloy
> ASM Failure Analysis Case Histories: Power Generating Equipment
Published: 01 June 2019
Fig. 14 Stress concentration at the bucket tip shroud due to presence of equiaxial and columnar grains
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Published: 01 January 2002
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in Three-Wheel Motorcycle Frame Failures and Redesign
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1993
Fig. 8 Methods of tube joining. (a) Fishmouthing. (b) Reduction of stress concentration using fillets
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Published: 15 May 2022
Fig. 3 Finite element analysis (FEA) model illustrating the stress concentrating effect of geometry and the importance of proper use of modeling tools. Without proper mesh definition, the tool will underestimate the maximum stress associated with the corner, which may result in a design
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.machtools.c0047779
EISBN: 978-1-62708-223-5
... concentration. To minimize this stress concentration, a larger radius fillet shaft at the critical change in section was suggested as corrective measure. Inclusions Stress concentration A6 UNS T30106 Fatigue fracture The shaft shown in Fig. 1 was part of a clamping device on a tooling assembly...
Abstract
Two A6 tool steel (free machining grade) shafts, parts of a clamping device used for bending 5.7 cm OD tubing on an 8.6 cm radius, failed simultaneously under a maximum clamping force of 54,430 kg. The shaft was imposed with cyclic tensile stresses due to the clamping force and unidirectional bending stresses resulting from the nature of operation. Nonmetallic oxide-sulfide segregation was indicated by microscopic examination of the edge of the fracture surface. Both smooth and granular areas were revealed on visual examination of the fracture. The shaft was subjected to a low overstress as the smooth-textured fatigue zone was relatively large compared with the crystalline textured coarse final-fracture zone. The fatigue crack was nucleated by the nonmetallic inclusion that intersected the surface and initiated in the 0.25 mm radius fillet at a change in section due to stress concentration. To minimize this stress concentration, a larger radius fillet shaft at the critical change in section was suggested as corrective measure.
Book Chapter
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0089738
EISBN: 978-1-62708-235-8
... that the crack in the header tube was the result of a stress concentration at the toe of the weld joining a doubler collar to the tube. The stress concentration was caused by undercutting from poor welding technique and an unfavorable joint design that did not permit a good fit-up. Recommendations included...
Abstract
While undergoing vibration testing, a type 347 stainless steel inlet header for a fuel-to-air heat exchanger cracked in the header tube adjacent to the weld bead between the tube and header duct. Investigation (visual inspection and liquid penetrant inspection) supported the conclusion that the crack in the header tube was the result of a stress concentration at the toe of the weld joining a doubler collar to the tube. The stress concentration was caused by undercutting from poor welding technique and an unfavorable joint design that did not permit a good fit-up. Recommendations included manufacturing the doubler collar so that it could be placed in intimate contact with the header duct, and a revised weld procedure was recommended to result in a smaller, controlled, homogeneous weld joint with less distortion.
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