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Engineering failure analysis
Elsevier Science
Engineering failure analysis

Elsevier Science

1350-6307

Engineering failure analysis/Journal Engineering failure analysisSCIEIISTP
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    Effect of some riveting process parameters on the fatigue life of double-shear lap joints

    Papuga, JanStejskal, Jiri
    25页
    查看更多>>摘要：ABS T R A C T Based on a motivating example, this review paper provides a survey of various parameters of a double-shear lap joint and of their effect on the fatigue life of such a joint. Because the common riveting characteristics that feature the size of the driven head and the residual stresses created are well known, the effects of cladding, anodizing, hole drilling, riveting, and coefficient of friction of adjacent surfaces are primarily evaluated. The results of various experiments in the gathered literature show that these secondary effects should not be simply neglected and that their research is still far from finished.
      原文链接:
    • NSTL
    • Elsevier

    A new model for bearing spall size estimation based on oil debris

    Madar, EyalGaliki, OfirKlein, RenataBortman, Jacob...
    13页
    查看更多>>摘要：This paper presents a study on damage severity estimation of spalled bearings based on an Oil Debris Monitoring (ODM). Several failure progression tests on angular contact ball bearings were performed. The spalls formed at the end of the tests were expanded over more then 180 degrees of the bearing race. Based on the ODM data analysis, it was possible to discriminate between the three stages of spall growth i.e., initiation, steady-state propagation, and accelerated propagation. A well-established dynamic model of bearings was used to simulate the dynamic behaviour of the angular contact ball bearing with a variety of spall sizes on the inner race. The analysis of the simulated signals from the model revealed that the transition from the steady-state to the accelerated propagation stages occurred at the arc length between two adjacent balls. This finding allowed the development of a new ODM model for spall size estimation in the accelerated propagation stage. The new ODM model relates the loss of mass from a bearing, as measured by an ODM sensor, to the size of the spall in the bearing. The ODM model considers the change in the spall geometry as the bearing deteriorates. The estimated spall size was in good agreement (maximum error of 13%) with the measured spall size at the end of the failure progression tests.
      原文链接:
    • NSTL
    • Elsevier

    Numerical optimisation of bonded joints for the manufacture of edge milling tools

    Correia, D. S.Marques, E. A. S.Carbas, R. J. C.das Neves, P. J. C....
    13页
    查看更多>>摘要：Edge milling tools for processing wood are currently assembled using brazing or fastening, joining the cutting insert to the tool body. However, the demand for lighter tools has led to a growing interest on changing this process to adhesive bonding. To determine the performance of the joint a cohesive zone model (CZM) was implemented, recurring to ANSYS (R) Mechanical (TM). To optimise its geometry, a parametric simulation was performed using a simplified single insert model of the full milling tool. Due to the large number of design points, a two-step approach was adopted, focusing on optimising certain parameters in each stage. For the loading condition, a rotational velocity test under overspeed condition, required by the relevant safety standard, was performed. Finally, in terms of output, the stresses generated, as well as differences in cost or manufacturing processes compared to the already commercialised tool configuration were analysed. The developed model highlighted the large safety factor present in the original, base-line design, demonstrating that adhesive bonding can lead to a highly durable and resistant milling tool. The developed model also allowed to optimise some of the key design parameters, while providing paths for minimising the tool's manufacturing cost and ensuring maximum performance.
      原文链接:
    • NSTL
    • Elsevier

    Investigation on failure mechanism of the square clinched joints with different sheet thicknesses

    Gao, XiaoleiChen, ChaoRen, XiaoqiangLi, Yuxiang...
    12页
    查看更多>>摘要：An experimental investigation was carried out to probe into the effect of the thickness arrangement on the failure mechanism and mechanical behaviour of the square joint produced by square clinching tools. Failure mode, geometrical characteristics and absorbed energy of the square joint were investigated to evaluate the quality of the square joint. Full shear and button separation are two major failure types observed in failure tests. The micro morphology of different joint fractures was studied by SEM. Lap shear load and lap tensile load of the square joint were measured during failure process. From the results, the fracture of joints with various sheet thickness arrangements shows typical ductile fracture characteristics. Interlock and neck thickness of the square joints in various thickness arrangements enlarge along with the gain of the top sheet thickness. Greater mechanical load-carrying ability and absorbed energy of the square joint were observed when the thicker sheet is on the top layer. Square clinching process can achieve the joining of Al5052-H32 sheets with dissimilar thickness arrangements reliably. Thicker sheets are suitable for being placed on the top layer during the square clinching process.
      原文链接:
    • NSTL
    • Elsevier

    Study on cracking process of hot pressed tee based on Fick's second law

    Zhu, XishanDeng, ChenquanDai, JinzheKuang, Yunkun...
    11页
    查看更多>>摘要：The microstructure, composition, hardness, stress and crack morphology of cracked tee in petrochemical plant were analyzed by optical microscope, scanning electron microscope, energy spectrum analysis and finite element analysis. The carbon content of decarburized layer was calculated by Fick's second law combined with Gauss error function. The accident tee was cracked due to decarburization. The decarburization stage is determined by morphology and composition analysis. The results show that the hardness near the crack is low, only a large amount of ferrite is left in the metallographic structure, and the content of pearlite is very little, which indicates that decarburization occurs during the manufacturing of the tee. Fick's second law combined with Gauss Error Function calculation proves that the carbon content is very low, resulting in the decrease of hardness. Through the finite element calculation, the stress near the crack is the largest. In addition, the crack is covered with a layer of uniform oxide, which proves that the crack occurrs in the early stage of pressing, decarburization and oxidation in the subsequent heat treatment process. Finally, the stress concentration occurres near the open crack, resulting in liquid leakage under the action of external liquid pressure in the process of hydrostatic test. This paper provides a method for researchers to calculate the carbon content of decarburization and judge the decarburization time.
      原文链接:
    • NSTL
    • Elsevier

    Ultrasonic fatigue of laser beam powder bed fused metals: A state-of-the-art review

    Avateffazeli, MaryamHaghshenas, Meysam
    36页
    查看更多>>摘要：Ultrasonic fatigue testing is a resourceful (time-and cost-saving) approach to assess the dynamic failure of materials in the gigacycle range (i.e., when the number of cycles to failure is beyond 10 million cycles). That is, ultrasonic fatigue is a popular tool of data collection that allows the testing of many cycles to occur in a small frame of time as the test specimen is cycled at an ultrasonic frequency of 20 kHz. The concept of very high cycle fatigue, which can be assessed through the ultrasonic fatigue testing method, has become an important point of learning for additively manufactured engineering structures and components that require long lives including automotive, aerial, and civil structures. Various additive manufacturing parameters contribute to the very high cycle fatigue response including the manufacturing process, material, size, and type of defects. This review aims at proving a background on the very high cycle fatigue, evaluating the governing mechanism of failure, and assessing the effect of manufacturing (i.e., laser beam powder bed fusion) parameters metallic materials. The special attention of this article is on the ultra-long fatigue response of laser powder bed fused metallic materials as the ultra-long fatigue domain is a less explored regime in revolutionary metal additive manufacturing. In terms of metal additive manufacturing, the focus of this paper is the laser beam powder bed fusion technique, being the most employed powder-based metal additive manufacturing process. The alloys that are reviewed in this article include AlSi10Mg, AlSi12, Ti6Al4V, stainless steel (i.e., 316L), and Ni superalloys (i.e., Inconel 718 and GH 4169) which are among the most popular and common alloys that are manufactured through the laser beam powder bed fusion process. This paper discusses the mechanism of crack initiation and characteristics (size, morphology, and location) of the defects in the microstructure that are responsible for the very high cycle fatigue failure. This paper extensively discusses the effect of additive manufacturing parameters on the very high cycle fatigue response of the mentioned alloys. Besides, the correlation between fractography aspects and stress intensity factors is discussed in this article. Finally, this review article provides an overview of future research trends and potential research opportunities of the VHCF of laser powder bed fused metallic materials.
      原文链接:
    • NSTL
    • Elsevier

    New design method of SET-Based on collapse strength under plastic formation

    Zhu, XiaohuaCheng, FeilongShi, ChangshuaiTan, Ling...
    16页
    查看更多>>摘要：Excellent collapse strength of solid expandable tubular (SET) after plastic forming is an advantageous guarantee for casing repair, plugging, repeating fracturing and other processes. This performance indicator is not only relevant to factors such as expansion, residual stress, and material, but also closely to the SET selected in the initial design. At present, there are few related studies on the initial design and selection of SET. This paper uses the CAE software to establish SET expansion to collapse process three-dimensional kinetics finite element model, and analyzes the collapse strength of different specifications under different expansion ratios, from the perspective of theoretical and simulation, derives the prediction formula. The results illustrate that the finite element simulation result of this paper and the error of the experiment is below 2%, the form of collapse is consistent with the experiment, the reliability is good; the wall thickness and expansion ratio parameters of the pipe have a more important impact on the types of collapse. When the SET specification is confirmed, the greatest collapse strength is presented a secondary relationship with the expansion ratio. Each specification of SET has the maximum collapse strength, its maximum value is closely connected to the wall thickness and expansion ratio, etc. Combined with a large number of simulation data obtained a linear fitting formula between the original radius ratio D-0/t and the optimum expansion ratio. This paper derives D-0 theoretical calculation formula based on maximum collapse strength by combination with the optimal expansion ratio, the nominal expansion ratio and geometric theoretical analysis. The results of this paper provide a certain theoretical guidance and research ideas for initial selection and design of SET.
      原文链接:
    • NSTL
    • Elsevier

    Post-mortem analysis of Cr2O3-Al2O3-ZrO2 refractory bricks used in an industrial opposed multi-burner gasifier

    Gao, JinghongSu, WeiguangSong, XudongBai, Yonghui...
    14页
    查看更多>>摘要：Periodical relining of the gasifier due to refractory corrosion and failure is a major cost driver in the coal gasification industry. In the present work, the failure mechanisms of Cr2O3-Al2O3-ZrO2 refractory bricks taken from different areas of an industrial opposed multi-burner (OMB) gasifier were investigated by post-mortem analysis. The results demonstrated that a densified (Mg, Fe)O-n (Al, Cr)(2)O-3 complex spinel layer was attained on surface of refractory, which inhibited the further infiltration of slag. The SiO2 and CaO in slag were the main corrosive components and infiltrated into the refractory through pores and cracks. Damage of used bricks was mainly due to crack growth as well as structural spalling caused by different thermal expansion coefficient of dezirconium layer, infiltration layer and original brick layer. In addition, the failure mechanisms of refractory bricks in different areas were also different owing to unique flow field and structure of OMB gasifier. The dome brick has the smallest wear, which was mainly destroyed by thermal corrosion, the strong scouring of upward flow unit and folded back flow unit. The sidewall brick was damaged by the scouring of high-speed airflow, chemical corrosion and high temperature creep. The damage of lower cone brick was mainly caused by strong mechanical scouring and structural spalling, which has the shortest service life.
      原文链接:
    • NSTL
    • Elsevier

    Determination of the fatigue behavior of mechanical components through infrared thermography

    Faria, Jose J. R.Fonseca, Luiz G. A.de Faria, Alfredo R.Cantisano, Artur...
    13页
    查看更多>>摘要：The determination of the fatigue behavior at a component level usually requires dedicated test rigs and an expressive amount of time. The hours spent on such machinery are expensive; therefore, solutions to reduce experimentation time are most welcomed. In this context, this investigation aims at developing a procedure for rapid determination of the fatigue strength of crankshafts by means of a thermographic methodology. The use of infrared cameras for fatigue strength analysis was first assessed in standard dog-bone specimens. Crankshafts were then tested in an in-house fatigue test rig using the conventional staircase method and the thermographic method. Sample batches with different manufacturing parameters were produced and tested to assess the robustness of the proposed alternative technique. Results of the dog-bone test campaign revealed a good correlation between fatigue strength estimates obtained with the conventional Wo center dot hler curve and the thermographic methodology. Finally, the thermographic technique also delivered results in close agreement with the staircase method for all crankshaft batches. The proposed procedure was found to be a viable, rapid alternative to conventional fatigue test programs, with potential application for complex structural components such as crankshafts, among others.
      原文链接:
    • NSTL
    • Elsevier

    Application of 8D methodology: An approach to reduce failures in automotive industry

    Divanoglu, Sevilay UsluTas, Ulge
    10页
    查看更多>>摘要：The policy of quality enhancement in the production process within the entire has a critical role. This study was focused on quality management as a case study in the automotive industry using 8D methodology. Thus, it was considered as a quality process where 8D problem-solving occurrences were not for a failure item, but all chronic problems. The originality of the study eliminates active and recurring failures by using the 8D methodology. In addition, this is an original study that provides an analysis of existing technologies as Value Stream Mapping (VSM) and Failure Mode Effect Analysis (FMEA) within the 8D concept in terms of offering a new model and proposing an effective methodology. The purpose of this study is to minimize quality failures and increase the efficiency of the method within the framework of lean production by using the 8D methodology, which includes quality techniques such as Failure Mode Effect Analysis (FMEA) in the automotive industry. As a result of this study, it was determined that by applying the 8D methodology, the total parts per million (ppm) was reduced to about 0.00 from 1,071 and this improvement resulted in savings. It can be claimed that 8D can be used as a quality management method in process improvement.
      原文链接:
    • NSTL
    • Elsevier