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Chap 3-3 (Shaft Failures)

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89 views13 pages

Chap 3-3 (Shaft Failures)

Uploaded by

Abeyu Assefa
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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• typically circular cross section that rotates

Shaft and is used to transmit power, but can be

non round and stationary


• Associated Parts—gears, sheaves (pulleys),
sprockets, bearings, snap rings, mating
gears, belts, chains

1
Shafts function in a wide ranging
operation conditions like
- corrosive environments,
- high and low temperatures, and
- abrasive environments.

As the industrial arena grows more


sophisticated, it seems as though
operations are confronting fewer and
fewer broken machine shafts. When
shafts DO break, however, there are
almost always as many theories
regarding the suspected culprits as
there are people involved.

2
Shaft

failures
Shafts are subjected to various types of
loading conditions and experience
- tension,
- compression,
- bending,
- torsion, or
any combination of these loading conditions.
These loads can be
- stationary (static), or
- may vary with time (dynamic)
introducing fluctuation.
In addition, shafts are subjected to
vibratory stress conditions.
Added to the service conditions, these load
conditions are sources of shaft failures.
The basic causes of shaft failures are
wear, fatigue and misalignment.
3
Shaft failures due to wear
- Wear is a common cause of shaft failures.
- The wear process takes place by abrasive wear mechanism
which is followed by removal of material from the surface of
the shaft.
- Abrasive wear normally occurs due to hard particles of
protuberances sliding along the surface.
- Presence of foreign particles such as sand, dirt, metallic
particles, wear debris in lubricant also results in abrasive
wear.
- Abrasive wear reduces shaft size and destroys shape of the
shaft and causes shaft failure.

4
Fatigue failure
- One of the more common causes
of shaft failure is fatigue.
- Fatigue failures commonly
initiate at stress raisers.
- The mechanism of fatigue
requires the simultaneous
presence of three things:
- there must be cyclic
stresses
on the shaft;
- these stresses must be
tensile in nature; and
- there must be plastic
strain.

5
Fatigue failure
The process of fatigue is considered to
consist of three stages:
- initial fatigue damage involving
plastic strains leading to crack
initiation;
- crack propagation that continues to

grow across the part until


the remaining cross section of
shaft becomes too weak to
carry the imposed loads; and
- final and sudden fracture of the
remaining cross section, due to
overload.

6
Fatigue failure
- These stresses occur at stress raisers
where the crack initiates.
- Some typical shaft features that act as
stress raisers are
- corners, fillets, notches, etc.,
- key-ways, grooves, splines, etc.,
- press- or shrink-fits,
- welding defects,
- metallurgical defects
introduced
by metal working such as
forging, machining, heat
treatment, etc. 7
c. Shaft failures due to misalignment
- Another common cause of shaft failures is misalignment.

- Misalignment can be introduced due to the following problems:


- mismatching of mating parts,
- original assembly error of equipment,
- any maintenance activity resulting in maintenance-
induced alignment problems,
- deflection or deformation of supporting components,
- deflection or deformation of the shaft itself.

8
Other shaft failures
Other shaft failures which need
attention from assembly, operation
and/or maintenance points of view
are the following.
- Accidental overload
- Corrosion due to working
environment
- Creep stress rapture
- Brittle fracture
- Bearing failures
- Metallurgical and manufacturing

defects
- Fits and tolerances between shaft

and hub
- Hydrogen embrittlement
9
- Excessive belt tension, overload.
Remedies of shaft failures
- Basic shaft failures can be prevented by identifying the cause that
are responsible for the failure and eliminating the conditions that
create these causes.
- Some of the remedies for preventing shaft failures are the
following.
- Wear of shafts can be reduced/prevented by using proper
lubrication in which the lubricant acts as a wear
deterrent and also as a cleaning agent.
- Misalignment can be eliminated by proper assembly
procedures.

10
Remedies of shaft failures
Fatigue can be reduced by proper design of local areas
known as stress raisers; i.e. by streamlining the part
at the change of cross section.
- Avoiding sharp surfaces during machining as
much as possible eliminates the formation of
stress raisers.
- Use of proper fits and tolerances reduces
fretting problems and misalignment, wear
and fatigue.

11
Importance of Shaft Alignment

- In very broad terms, shaft misalignment occurs when the


center-lines of rotation of two (or more) machinery shafts
are not in line with each other.

12
Principal Causes of Misalignment

 Lack of appropriate Standards and


Specifications
 Poor Tolerances and Poor Methods
 Good Methods, but bad practices
 Lack of understanding of precision process
 Dynamic movement (thermal growth, pipe
strain etc.)
 Mis-diagnosis with Unbalance or Looseness

13

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