FAILURE ANALYSIS OF MACHINE SHAFTS

Whether related to motors, pumps or any other types of industrial machinery, shaft failure analysis is frequently misunderstood, and often being perceived as difficult and expensive. Analysis should be relatively straight forward in most most machine shafts, however, since the failure typically provides strong clues to the type and magnitude of forces acting on the shaft and the direction they acted in. The failed part can therefore tell exactly what happened. At this point, it's also necessary to say that caution on interpreting the clues needs to be taken, while the oldest part of a fatigue failure typically has the smoothest surface on at least 98% of the time – it's still crucial to look carefully at the failed part in the area of the origin. The shaft surface will describe the force. A crack always grows perpendicular to the plane of maximum stress. Therefore, if we can determine the plane of maximum and minimum quality conditions of the shaft surface, we then can evaluate the most and least resistance to failure, which can be used to determine the reliability and life of the shaft as well as its original and final shaft surface conditions. Many times, we've seen shafts where the originating force was torsion with a sort of angular cracks, but the majority of crack propagation was in bending – fooling inspectors into thinking that bending was primary force. At this point, it is interesting to note that, it is a good thing to determine the maximum and minimum shaft surface conditions, but quite better to determine the conditions in between, which will help to know the reliability/life growth and degradation of shaft. The knowledge of the maximum, minimum and real-time points of shaft conditions will help to determine control limits, threshold , and failure points. Technological Inheritance Coefficients can be used to assess the operating conditions and performance of shafts, since technological inheritance is the transfer of the properties of object (e.g the shaft quality and process effectiveness parameters) from its initial to final operation of a technological system. Technological Inheritance Model can therefore be used to determine maximum and minimum reliability/life, reliability/life growth and degradation, threshold points and failures of shafts as well as to evaluate the effectiveness/efficiency of the process. The Knowledge of Reliability growth can be used to assess the optimum reliability of shaft for the best selection and purchase of shafts and equipment as well as knowing the Reliability degradation can be used to assess the failures of shafts and equipment. Real-Time Reliability/Effectiveness growth and degradation test during operation will definitely lead to a sustainable development in design, manufacturing, operation and maintenance.

MOVING FROM PHYSICAL TO VIRTUAL ASSESSMENT OF PROCESSES AND PARTS

The challenge for durability of part remains how to accelerate the analysis process. The minimum acceptable period for a “full” analysis is about 12 hours, which is equivalent to running the analysis over night. Operating computing together with parallel processing are ideally suited to meet the computational challenges because part fatigue life calculations are usually similar at each nodes or element (e.g part quality and process condition parameters). Selecting which part quality and process conditions are to be analyzed more intelligently as well as optimizing time history, quality parameters, process operating conditions and time reduction methods will go a long way towards meeting the challenge. Real-Time data acquisition of part quality and process condition parameters will add intelligence to fatigue life analysis within software application. The software should be able to choose the most cost effective fatigue life method for components and systems with regards to its development and service conditions. It will also help to keep records that explains why such cost effective selections are made. At this point, it is worthy to note that the change to a virtual development process has been driven by a number of factors, particularly reduced development time, increased model designs, increased complexity and the need to optimize performance and costs. These multiple factors have led the introduction of new methods that can address the actual durability and reliability problems. Since fatigue results are usually expressed in terms of the number of cycles or repeats of a particular loading sequence, required to reach a specific criterion at a location. The fact is that these results are sometimes associated with physical quantities such as hours, miles, fracture of a durability route. At the same time, it must be noted that, these results are of course sensitive to each of the major inputs, summed up in load, geometry and material that produce component and system life and reliability. The new failure mode analysis method should therefore take into consideration the compound resultant factor of load, geometry and material characteristics. The compound factor can be determined and assessed during development stages, which includes the initial, surface finish operations of parts and throughout the operations of a technological system as well as during the service operation of equipment. Analyzing more intelligently equipment part and process conditions with a technological inheritance assessment technique from the initial to final operation will help to meet the challenges of durability and reliability of component and system. Technological Inheritance is the transfer of the properties of part and process from the initial to final operation in a particular technological system. Technological Inheritance technique can be used to predict and determine the outcome of development and service operations. The outcome of a particular part surface finish can be optimized to produce maximum durability and life at minimum cost, which in turn is used to set up optimum safety controls and process conditions as well as determine optimum reliability of equipment parts and systems. The optimization results of the surface finish can also be used to determine the optimum points or levels of the operating service conditions. The sensitivity of these outcomes is assessed with reference to these optimum values and their variability. With the help of Technological Inheritance Model, it is possible to assess the sensitivity and variability of part surface quality and process condition parameters like reliability growth, degradation, failures and life of components/systems. Any variation from the optimum values can be captured, measured and monitored. Sensitivity to variation in loading magnitude is particularly acute due to logarithm relationship between load and life or reliability. 10% in load variation for example can alter predicted life or reliability by a factor of two. Overloading should not be permitted and should be controlled, wherever possible. From designer's point of view, variation in loading conditions are largely the results of variability in customer usage. To a large extent, this variability is said to be beyond the control of designers. Other than through the provision of adequate safety factors With Technological Inheritance Technique, Designers can now be equipped with software programs, testing devices and measuring instruments that can help to control the variability of parts and process conditions. If operators are given the right instruments and data acquisition devices that can read the condition variations from the initial to final operation, equipment life and reliability can be controlled. At this point, it is worth knowing that, the material behavior and impact of geometry on the other hand can usually be defined more precisely and the condition variability is usually more less than the associated with load, but the material and geometrical conditions must also be controlled to prevent and eradicate hidden failures with the help of Technological inheritance model through the technological and service operations. Technological Inheritance Model, Yi = aYi-1b, where Yi – the final quality parameter of component (material and Part geometry), derived through physical measurement, Yi-1 – the initial quality parameter of component, derived through Regression equation of a part surface finish condition for a particular purpose and its physical measurement, a - technological inheritance coefficient for the transfer of component quality parameters from one point to the other and b - technological inheritance coefficient for the transfer of process condition parameters from one operation to operation. These coefficients can be used to convert physical to virtual measurements, integrate multiple parameters into a single factor,, used to set up threshold points and control limits. Technological inheritance coefficients “a” and “b” range between 0.0 and 1.0, where 0.0 represents minimum, and 1.0 as maximum values of the physical parameters in the model. The real-time data of the inheritance model can be used to design reliability/life software programs, measuring instruments for reliability/life, and for inspecting, testing and monitoring devices of reliability/life.

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