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Engineering Material -Group 5

Baba Engineering company have aproblem of broken shaft (fatiguephenomenon)

Conduct! "ailure #nalysis

$! %ecommendation on Materials

&! %ecommendation on 'esign

! %ecommendation on Environment

By

 *#+ 'E, #++,. #M#' '#+,#/ +,. M0' +#1%2'',+

#M#' "#.%, 1# B,+ M0' 1#M12',+

#M#' #11#+,, B,+ #B 1#*#%

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"ailureanalysis

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Fracture Analysis• Machine components can fracture from either a single

overload force or from fatigue forces(uctuating loads).

'uctile 0verloads vs Brittle 0verload

'uctile overload!3Great deal of distortion31ome can break into 2 pieces because of great dealof distortion around the fracture face.

Brittle overload!3Breaks 4ith no visible distortion3 ,n a brittle overload failure separation

of the t4o halves isn’t quite instantaneous  but proceeds at a tremendous rate  nearly at the speed of sound in the !aterial.

3"racture like a glass

Very

Ductile

Moderately

DuctileBrittle

Fracture

behavior :

"ingle #verload Failures

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Fatigue Failures3"atigue cracks take ti!e to gro$ across a part!

3,n so!e case a crack that $ill not result in acatastrophic failure for millions of cycles!3 *he fatigue %one is typically !uch s!oother than theinstantaneous %one 4hich is usually brittle and crystalline inappearance!

36rogression marks are an indication that the gro$th ratechanged as the crack gre4 across the shaft and don’tappear on !any failure faces.

Figure & sho4s a simple fatigue crack 4iththe di7erent gro4th 8ones and the ma9orphysical features!

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&hat type of load $as it'

o$ heavily $as it loaded'3,nstantaneous 8one (,:) carries the load inthe instant before the part breaks!3 By looking at the si%e of the * youcan tell the !agnitude of the load onthe part!

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%ecommendation0fmaterial

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"+GG,"-, /A-,0A1 F#0 -,

0#31,/

High Strength Stainless Steel (17-4 PH)

• 17-4 PH is a chromium-nickel grade of stainless.

• 17-4 PH should not be used in the solution treated condition.

• The strength and corrosion resistance properties of 17-4 hold up well.

• 17-4 machines well, has excellent welding characteristics, and forges easil.

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4ondition-ensile

"trength (")

 5ield "trength

(")

"hear

"trength (")

,longation in

26ardness

A (annealed) 5;;;; ;;;; ; ; &

788 (hardened at

7889 F)$;;;;; ; &&

/,4A

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#66/,C#*,0+1

• 17-4 is used where high strength and good corrosion resistance are re!uired.

• "uitable for intricate parts re!uiring extensi#e machining and welding, and$or

where distortion in con#entional heat treatment is a problem.

•   The corrosion resistance of 17-4 is superior to that of hardenable straight

chromium grades such as 41%.

• &ommon applications include uses in aircraft and gas turbines, nuclear reactors,

 paper mills, oil field industr, and chemical process components.

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E#* *%E#*,+G

• &ondition H '(() - '(() * for 1 hour, air cool. +ockwell & 44 a#erage

• &ondition H11()- 11() * for 4 hours, air cool. +ockwell & a#erage

•nnealing /&ondition 0

The annealing /solution treatment0 temperature is 1'(() *, followed b air cooling.

aximum 2rinell hardness at mid-radius is %.

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%ecommendation0fdesign

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Mechanical 6roperties

• 1trength $ stress at any location of the shaft should

not e?ceed the yield strength of the

material

• 1ti7ness $ depends on the allo4able de@ection and

t4ist of the shaft!

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Mechanical 6roperties

•  *he strength of a material plays animportant role is designing a goodshaft!

• Basically the state of stress to beconsidered is caused by $ Bending A due to its 4eight or load

 $ #?ial /oading

 $ *orue A that being transmitted to theshaft

 $ Combination of bending a?ial loading

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E+,%0+ME+*

"#C*0%

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• %arsh environmental conditions

lead to failure

• &'treme heat or cold

• (ycling stresses and a(orrosive environment

INVOLVING

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PROTECTION POSSIBILITIES

• )rotection against corrosion#

• Monitor e'treme or fre*uent changes in

temperature pressure#

• )rotection against +V light or other

harmful sources#

• Maintain the natural fre*uency of the

structure#

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%eferencing

 • http444!maintenancetechnology!com$;$;Ffailure-analysis

-of-machine-shafts• http444!plant-maintenance!comarticlesrcfa!shtml

•http444!speedymetals!cominformationMaterial$!html• http444!appliedultrasonics!comblogfatigue-failurepreventing-fatigue-failure-4ith-ultrasonic-impact-treatment

• http444!appliedultrasonics!comblogfatigue-failurepreventing-fatigue-failure-4ith-ultrasonic-impact-treatment

• http444!appliedultrasonics!comblogfatigue-failurepreventin

g-fatigue-failure-4ith-ultrasonic-impact-treatment

http://www.maintenancetechnology.com/2012/07/failure-analysis-of-machine-shafts/http://www.maintenancetechnology.com/2012/07/failure-analysis-of-machine-shafts/http://www.plant-maintenance.com/articles/rcfa.shtmlhttp://www.speedymetals.com/information/Material2.htmlhttp://www.appliedultrasonics.com/blog/fatigue-failure/preventing-fatigue-failure-with-ultrasonic-impact-treatmenthttp://www.appliedultrasonics.com/blog/fatigue-failure/preventing-fatigue-failure-with-ultrasonic-impact-treatmenthttp://www.appliedultrasonics.com/blog/fatigue-failure/preventing-fatigue-failure-with-ultrasonic-impact-treatmenthttp://www.appliedultrasonics.com/blog/fatigue-failure/preventing-fatigue-failure-with-ultrasonic-impact-treatmenthttp://www.appliedultrasonics.com/blog/fatigue-failure/preventing-fatigue-failure-with-ultrasonic-impact-treatmenthttp://www.appliedultrasonics.com/blog/fatigue-failure/preventing-fatigue-failure-with-ultrasonic-impact-treatmenthttp://www.appliedultrasonics.com/blog/fatigue-failure/preventing-fatigue-failure-with-ultrasonic-impact-treatmenthttp://www.appliedultrasonics.com/blog/fatigue-failure/preventing-fatigue-failure-with-ultrasonic-impact-treatmenthttp://www.appliedultrasonics.com/blog/fatigue-failure/preventing-fatigue-failure-with-ultrasonic-impact-treatmenthttp://www.appliedultrasonics.com/blog/fatigue-failure/preventing-fatigue-failure-with-ultrasonic-impact-treatmenthttp://www.appliedultrasonics.com/blog/fatigue-failure/preventing-fatigue-failure-with-ultrasonic-impact-treatmenthttp://www.appliedultrasonics.com/blog/fatigue-failure/preventing-fatigue-failure-with-ultrasonic-impact-treatmenthttp://www.speedymetals.com/information/Material2.htmlhttp://www.plant-maintenance.com/articles/rcfa.shtmlhttp://www.maintenancetechnology.com/2012/07/failure-analysis-of-machine-shafts/http://www.maintenancetechnology.com/2012/07/failure-analysis-of-machine-shafts/

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 *he end *hank you