Pump shaft failures — a compendium of case studies

Berndt, F; Bennekom, A. van

doi:10.1016/s1350-6307(99)00043-6

Cited by 49 publications

(15 citation statements)

References 1 publication

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“…A granular crack surface was observed, indicating the flange experienced a brittle failure which is the typical failure of cast steel (Batdorf, 1975). In fact, similar keyway failure has been reported by many researchers such as keyway failure in bridge crane shaft (Zambrano, et al, 2014), high-speed shaft of pump (Li, et al, 2016;Berndt, et al, 2001), and elevator drive shaft (Göksenli, et al, 2009). …”

Section: Introductionsupporting

confidence: 60%

Failure Investigation of Plastic Shredding Machine’s Flange Coupling Based on Mechanical Analysis

Nurprasetio

Budiman²,

Triawan

2017

IJOST

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This paper presented the investigation of failure mechanism of plastic shredding machine's flange coupling which is made of cast steel. The machine unexpectedly stalled a few minutes after High-Density Polyethylene (HDPE) plastic bottles were fed into the machine. It was discovered afterward that the flange broke with the large crack surface. Finite element analysis (FEA) was performed to find the position and value of the critical stresses in the flange during operating condition. Subsequently, hardness test was conducted on the flange body to determine the Brinell hardness which was then converted into the approximate ultimate tensile strength (σu). As a result, a maximum Von Mises stress of 287 MPa was confirmed from the FEA to be concentrated in the flange's keyway. Although this was found to be lower than the approximate σu obtained from hardness testing i.e. 449 MPa, the critical stress indicated an unstable condition which may induce a crack initiation any time when vibration or dynamic load occurs. Based on these analyses, it was concluded that the failure had been initiated by dynamic rather than static loading generated during machine stall condition. The dynamic load caused crack initiation at a stress concentration point of the keyway. The crack then propagated rapidly, breaking the flange body.

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Section: Introductionsupporting

confidence: 60%

Failure Investigation of Plastic Shredding Machine’s Flange Coupling Based on Mechanical Analysis

Nurprasetio

Budiman²,

Triawan

2017

IJOST

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“…Over-heating of the journal surface assembled with sleeve decreased the fatigue strength of the journal surface. In addition, the root fillet region by which stress concentration is created [2] also facilitates the fatigue crack initiation.…”

Section: Failure Causesmentioning

confidence: 99%

“…The hardness of core material is specified as HRC25-30 and some journals of main shaft are to be induction-quenched (journals A, C, D, and E, marked in Figs. 1,2) to obtain the surface hardness of HRC56-62. The failed sleeve was made of 38CrMoAl steel.…”

Section: Introductionmentioning

confidence: 99%

Failure Investigation of a Locomotive Turbocharger Main Shaft and Bearing Sleeve

Zhang

Guo

2010

J Fail. Anal. and Preven.

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A failure investigation was conducted on a locomotive turbocharger main shaft and a bearing sleeve which had been assembled with the main shaft. The fracture of the main shaft took place at a sharp edged groove between two journals with different cross-sectional areas.The dominant failure mechanism of the main shaft was low-cycle and rotation-bending fatigue. Wear failure occurred on the bearing sleeve through a mixed mode of abrasive and adhesive wear. Detailed metallurgical analysis indicated that the bearing sleeve and the journal surface assembled with the sleeve had been subjected to abnormally high temperatures which led to increased friction between the bearing sleeve and the bearing bush, the sleeve, and the journal surface. In addition, the abnormally high temperature softened the induction-hardening case on the journal surface and decreased the fatigue strength. Fatigue crack initiation occurred at the root fillet of the groove because of the stress concentration in that area.

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“…However, the new requirements imposed by the energy market for pumped storage hydropower plants have induced additional technical problems with the units' maintenance of shafts due to fatigue. In literature, other studies present aspects of the pump shaft failure in operating condition . An analysis of the premature failure of two counter shafts used in centrifugal pumps for lifting slurry has been carried out by Das et al A collection of pump shaft failures due to corrosion, fatigue and sleeve failures is presented by Berndt and van Bennekom …”

Section: Introductionmentioning

confidence: 99%

Failure assessment of the shaft of a pumped storage unit

Negru

Muntean²,

Pasca

et al. 2014

Fatigue Fract Eng Mat Struct

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The paper is focused on failure assessment of the shaft of a pumped storage unit. The shaft failure occurred during normal operation of the hydropower unit after 35 years of service. Three different methods are applied in order to assess its lifetime. Firstly, a finite element analysis was performed in order to obtain the static stress distribution and to apply a strain‐based crack initiation for the shaft under torsion load. The number of cycles for crack propagation was obtained using the Paris law for mode III. More precisely, the lifetime assessment of the shaft is obtained based on a low‐cycle fatigue analysis for estimating the number of cycles for crack initiation and then followed by that for fatigue crack propagation. Secondly, an analytical estimation based on failure assessment diagram is carried out for circumferential crack in order to determine the safe/unsafe region, where the shaft can operate with a crack. The failure assessment diagram for mode III loading was plotted in order to obtain the critical circumferential crack using the stress intensity factor solution and three analytical solutions for plastic zone. Thirdly, the theory of critical distance is employed for estimating the shaft life under torsional loading. A good agreement is obtained between the estimated results and experimental data for the shaft life and the crack length.

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Pump shaft failures — a compendium of case studies

Cited by 49 publications

References 1 publication

Failure Investigation of Plastic Shredding Machine’s Flange Coupling Based on Mechanical Analysis

Failure Investigation of Plastic Shredding Machine’s Flange Coupling Based on Mechanical Analysis

Failure Investigation of a Locomotive Turbocharger Main Shaft and Bearing Sleeve

Failure assessment of the shaft of a pumped storage unit

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