Failure analysis of a failed connecting rod cap and connecting bolts of a reciprocating compressor

Zhu, Xiaolei; Xu, Jinjun; Liu, Yang; Cen, Bo; Lu, Xiaofeng; Zhang, Zhuo

doi:10.1016/j.engfailanal.2017.01.016

Cited by 20 publications

(6 citation statements)

References 14 publications

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“…It has been suggested that engine collapse was caused by the forming laps in the grooves of the bolt shank. Zhu et al [26] made a failure analysis of the connecting rod cap and connecting bolts for a reciprocating compressor. The reasons for the failure of the connecting rod cap and connecting bolts as a result of operation for approximately 175.200 hours were researched.…”

Section: Article Info Abstractmentioning

confidence: 99%

Investigation of failure mechanism of a DCI engine connecting rod

Gök¹,

Cihan²

2021

European Journal of Technic

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Section: Article Info Abstractmentioning

confidence: 99%

Investigation of failure mechanism of a DCI engine connecting rod

Gök¹,

Cihan²

2021

European Journal of Technic

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“…Failure of bolts and bolted connections occurs in different types of structures, like steel concrete composite beams (Zhang et al, 2019), beam to column assemblies (Grimsmo et al, 2016), filter press (Molaei et al, 2015), helicopter gearbox support strut (Krstic et al, 2016), compressor (Zhu et al, 2017), Francis turbine (Casanova and Mantilla, 2018) and submersible pump (Escobar et al, 2016). Failure investigations show different types of fracture mechanisms static shear and bending (Zhang et al, 2019) or tensile (Grimsmo et al, 2016), fatigue (Molaei et al, 2015;Zhu et al, 2017;Casanova and Mantilla, 2018) and stress corrosion cracking (Krstic et al, 2016;Escobar et al, 2016).…”

Section: Structural Integritymentioning

confidence: 99%

Rainwater propeller pumps structural integrity

Galatanu

Muntean

Marșavina

et al. 2019

IJSI

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Purpose The purpose of this paper is to focus on the structural integrity of the rainwater propeller pumps installed in the municipal wastewater treatment plant (WTP). Design/methodology/approach A numerical analysis is performed to determine the maximum shear stress on the fasten bolts. The rainwater propeller pump is examined in operation at normal conditions and when one blade is progressively blocked. Findings The failure mechanism of the rainwater pump impeller is determined. Research limitations/implications The fibbers and wastes are discharged together with rainwater during storms with these types of pumps to avoid the flood of the WTP. Several catastrophic events have occurred in service due to the fibbers clog the gap between the impeller blades and the pump casing. The clogging process is partially understood so actual technical solutions deal with effects rather the main causes. Practical implications The operation time of all seven rainwater pumps installed in Timisoara’s WTP is investigated. Climate changes in Banat region and new waste properties found in the wastewater require appropriate technical solutions. A technical solution is proposed based on these investigations to extend the operation time and to diminish the operation and maintenance costs. Social implications These large pumps are installed in the urban sewage centralised system implemented in the most cities. The access to the sewerage network is a requirement of any community, regardless of the social status. Originality/value The fracture surfaces of both fastening bolts of the rainwater pump impellers produced in service are examined. As a result, it has been identified that the catastrophic events are due to the brittle fracture of both fasten bolts between the impeller blades and the pump hub, respectively. The catastrophic events of the rainwater propeller pumps are directly correlated to the clog level of the impeller. The numerical simulation is performed to determine the maximum shear stress on the fasten bolts. The case with pump operating at normal conditions is performed identifying its vulnerabilities to clog conditions. Next, one impeller blade is progressively blocked considering three time stop scenarios associated with different clog levels. Conclusively, the operating time of the rainwater pump up to the catastrophic failure is correlated to the clog level of the impeller.

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“…They recommended increasing the fillets at the connecting rod at the points having highly concentrated stresses. Zhu et al [8] investigated the failure problem for a connecting rod cap and bolts installed in a reciprocating compressor. The investigation was performed using a scanning electron microscope, an optical microscope, and finite element analysis technique.…”

Section: Introductionmentioning

confidence: 99%

Enhancing the Durability of Connecting Rod of a Heavy-Duty Diesel Engine

Ismail¹,

Abdelrazek²,

Ismail³

et al. 2021

IJAME

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This paper investigates the mechanical loads resulting from the combustion pressure and dynamic inertia and their effects on the connecting rod of a direct injection turbocharged diesel engine. The main purpose is to enhance the durability of the connecting rod in order to withstand more engine power increase. The distribution of the axial (compressive/tensile) stress, deformation, and safety factors are calculated in order to predict any possible mechanical failure. The finite element routine is used by ANSYS Workbench to analyse the loading on the connecting rod model. The current study is applied to the connecting rod of a 300 hp diesel engine in order to increase the engine power by 17%. The connecting rod operates safely and withstands the applied loads until the power increase reaches 72%. The most stressed points are at the connecting rod shank, while less stressed are experienced at the big end. Calculations show that introducing some changes to the connecting rod geometry may result in decreasing the excessive stresses. These changes include increasing the thickness of the shank cross-section, increasing the fillets radii and slightly reducing the dimensions of the big end in order to maintain the same mass. The new geometry could significantly reduce the maximum stress by 25.5% with an insignificant reduction in the total mass of the connecting rod.

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Failure analysis of a failed connecting rod cap and connecting bolts of a reciprocating compressor

Cited by 20 publications

References 14 publications

Investigation of failure mechanism of a DCI engine connecting rod

Investigation of failure mechanism of a DCI engine connecting rod

Rainwater propeller pumps structural integrity

Enhancing the Durability of Connecting Rod of a Heavy-Duty Diesel Engine

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