Search results for: Urbi Pal

Authors: Piyas Palit, Urbi Pal, Jitendra Mathur, Santanu Das

Abstract:

Bearing is an important machinery part in the industry. When bearings fail to meet their expected life the consequences are increased downtime, loss of revenue and missed the delivery. This article describes the failure of a gearbox bearing in rolling contact fatigue. The investigation consists of visual observation, chemical analysis, characterization of microstructures using optical microscopes and hardness test. The present study also considers bearing life as well as the operational condition of bearings. Surface-initiated rolling contact fatigue, leading to a surface failure known as pitting, is a life-limiting failure mode in many modern machine elements, particularly rolling element bearings. Metallography analysis of crack propagation, crack morphology was also described. Indication of fatigue spalling in the ferrography test was also discussed. The analysis suggested the probable reasons for such kind of failure in operation. This type of spalling occurred due to (1) heavier external loading condition or (2) exceeds its service life.

Keywords: bearing, rolling contact fatigue, bearing life

Procedia PDF Downloads 172

Authors: Urbi Pal, Piyas Palit, Jitendra Mathur, Abhay Chaturvedi, Sandip Bhattacharya

Abstract:

The hot rolled slab lifting crane cable reel drum (CRD) failed due to failure of cable reel flat spring which are inside the cassette of CRD. CRD is used for the movement of tong cable. Stereoscopic observation revealed beach marks and Scanning Electron Microscopy showed striations confirming fatigue mode of failure. Chemical composition should be spring steel (Cr-Mo-V) as per IS 3431:1982 instead of C-Mn steel. To find out the reason of fatigue failure, the theoretical fatigue life of flat spiral spring has been calculated. The calculation of number of fatigue cycles included bending moment, maximum stress on the spring, ultimate tensile strength and alternative stress. The bending moment determination has been taken account with various parameters like Young’s Modulus, width, thickness, outer diameter, arbor diameter, pay out the length and angular deflection in rotations. With all the required data, the calculated fatigue life turned to be 10000 cycles, but the spring served 15000 cycles which clearly indicated beyond fatigue life usage. Different UTS values have been plotted with respect to the number of fatigue cycles and clearly showed that the increase in UTS by 40% increases fatigue life by 50%. The significance of higher UTS lied here, and higher UTS depends on modified chemistry with proper tempered martensite microstructure. This kind of failure can be easily avoided by changing the crane spring maintenance schedule from 2 years to 1.5 years considering 600 cycles per month. The plant has changed changing the schedule of cable reel spring and procured new flat reel spring made of 50CrV2 steel.

Keywords: cable reel spring, fatigue life, stress, spring steel

Procedia PDF Downloads 156