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tool failure

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Series: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001805
EISBN: 978-1-62708-241-9
...Abstract Abstract Several surgical tool failures were analyzed to understand why they occur and how to prevent them. The study included drills, catheters, and needles subjected to the rigors of biomedical applications such as corrosive environments, high stresses, sterilization, and improper...
Image
Published: 30 August 2021
Fig. 1 Cutting tool failure modes. (a) Characteristic wear and fracture surfaces on cutting tools. (b) Catastrophic failure. (c) Typical wear measurements for a turning tool. VB , flank wear More
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001121
EISBN: 978-1-62708-214-3
...Abstract Abstract An AISI D2 tool steel insert from a forming die used in the manufacture of automotive components failed prematurely during production. Results of various analyses and simulation tests indicated fatigue failure resulting from improper heat treatment. The fatigue fracture...
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
... specified for the shafts was a free-machining grade of A6 tool steel. Fig. 1 A6 tool steel tube-bending-machine shaft that failed by fatigue fracture. Section A-A: Original and improved designs for fillet in failure region. Dimensions are in inches. View B: Fracture surface showing regions of fatigue...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0006436
EISBN: 978-1-62708-217-4
...Abstract Abstract A failed H-11 tool steel pylon attachment stud was found during a routine walk-around inspection. The stud exhibited gross localized corrosion pitting at several different areas on its surface. Light general rust was also evident. Severe pitting occurred near the fracture...
Image
Published: 30 August 2021
Fig. 29 Failure caused by improper quenching. (a) AISI W1 tool steel wire-forming die that broke prematurely during service. (b) Cold etching (10% aqueous nitric acid) of a disk cut behind the fracture revealed that the bore working surface was not hardened; only the dull gray region More
Image
Published: 30 August 2021
Fig. 43 Die failure caused by severe wear. (a) Die made from air-hardening tool steel that exhibited a crazed and eroded condition. Areas A and B are shown in (b) and (c), respectively. Original magnification of both: 10×. (d) Microstructural examination of area B revealing a layer of as-quenched More
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001814
EISBN: 978-1-62708-180-1
...Abstract Abstract This article describes the characteristics of tools and dies and the causes of their failures. It discusses the failure mechanisms in tool and die materials that are important to nearly all manufacturing processes, but is primarily devoted to failures of tool steels used...
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006818
EISBN: 978-1-62708-329-4
...Abstract Abstract This article discusses failure mechanisms in tool and die materials that are very important to nearly all manufacturing processes. It is primarily devoted to failures of tool steels used in cold working and hot working applications. The processes involved in the analysis...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0009222
EISBN: 978-1-62708-180-1
...Abstract Abstract This article describes the six fundamental factors that decide a tool's performance. These are mechanical design, grade of tool steel, machining procedure, heat treatment, grinding, and handling. A deficiency in any one of the factors can lead to a tool and die failure...
Series: ASM Handbook
Volume: 11A
Publisher: ASM International
Published: 30 August 2021
DOI: 10.31399/asm.hb.v11A.a0006826
EISBN: 978-1-62708-329-4
... preventive measures workpiece failures Machining-Related Failures Machining-related failures may be characterized as: Machining workpiece (in-process) failures: Machining condition and parameters contributing to (in-process) workpiece failures: Machine tool, cutting tool, cutting fluid...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.machtools.9781627082235
EISBN: 978-1-62708-223-5
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0048139
EISBN: 978-1-62708-225-9
... by fatigue and was initiated at tool marks. Corrective Measures The spring-winding operation was altered to eliminate the tool marks. No further fatigue failures of the toggle-switch springs occurred. Selected Reference Selected Reference • Fatigue Failures , Failure Analysis and Prevention...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.machtools.c0089456
EISBN: 978-1-62708-223-5
... was observed. The fracture was found to have originated near the high-stress region of the die face examination of the fracture surface. Failure of the die was concluded to have originated in an area of abnormally high hardness which is prone to microcracking during heat treatment for this grade of tool steel...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.machtools.c0047840
EISBN: 978-1-62708-223-5
... discharge machining Rockwell hardness AZ UNS T30102 Metalworking-related failures Fatigue fracture The mandrel shown in Fig. 1 was part of a rolling tool used for mechanically joining two tubes before they were installed in a nuclear reactor. The operation consisted of expanding the end...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003519
EISBN: 978-1-62708-180-1
...Abstract Abstract This article reviews the most common reasons for failures and the purpose of a failure investigation. It discusses the nine steps for the organization of a good failure investigation. The three basic tools that are helpful in any failure investigation, namely, a fault tree...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.machtools.c9001014
EISBN: 978-1-62708-223-5
... of adequate tempering was the secondary cause. Castings Porosity Prestressed concrete Shrinkage Stretching Tools Carburizing steel Casting-related failures This tool is used to stretch reinforcement wires in prestressed concrete. Reinforcement wires are apparently inserted into a hole...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0047673
EISBN: 978-1-62708-217-4
... and fusion-zone widths. The weld deficiencies were traced to problems in forming and fit-up of the C-shape members and to difficulties in alignment and positioning of the weld tooling. The failure of the resistance spot welds was attributed to poor weld quality caused by unfavorable fit-up and lack of proper...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0048134
EISBN: 978-1-62708-235-8
... was 0.46 mm (0.018 in.) in diameter and was in the spring-temper condition (tensile strength, 1000 MPa, or 145 ksi). Fig. 1 Phosphor bronze (C51000) spring that failed prematurely during fatigue testing. Failure was due to the presence of a tool mark (indentation) at a bend. (a) Setup for fatigue...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001212
EISBN: 978-1-62708-235-8
.... It was concluded that the numerous hardening cracks were caused by abrupt quenching from over-heating temperature and by local stress concentrations due to indentations of the tool caused during alignment. Cracking (fracturing) Flame hardening Quenching C45 Heat treating-related failures Operation...