Failure analysis by keyway stress concentration of a pickling decoiler machine output shaft

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis Pub Date : 2025-03-09 DOI:10.1016/j.engfailanal.2025.109515

Pedro R. da Costa , M. Freitas

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引用次数: 0

Abstract

In July 2021, an intervention and fracture analysis were conducted following the failure of a shaft in a pickling decoiler box machine. Mechanical hardness and chemical composition measurements, performed in the owner’s laboratories, revealed that the shaft was made of low-alloy steel containing chromium (Cr) and molybdenum (Mo), similar to 42CrMo4 (DIN standard) or 4140 (AISI standard), quenched and tempered. Close inspection of the fracture surface indicated that failure originated from rotating bending efforts. The combination of the rotary bending stresses with two stress concentration effects − one due to a keyway and another due to a diameter transition −resulted in localized stresses exceeding the material’s estimated fatigue endurance. The resulting high local stress caused multiple fatigue crack initiation points along the shaft perimeter, leading to progressive crack growth and eventual failure. Finite element analysis characterized the two stress concentration factors, revealing that the keyway had the most significant impact. To address the issue, an in-depth analysis of the keyway’s bending stress concentration factor and the associated stress distribution was conducted, culminating in the proposal of a new keyway location and geometry.

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来源期刊

Engineering Failure Analysis 工程技术-材料科学：表征与测试

CiteScore

7.70

自引率

20.00%

发文量

956

审稿时长

47 days

期刊介绍： Engineering Failure Analysis publishes research papers describing the analysis of engineering failures and related studies. Papers relating to the structure, properties and behaviour of engineering materials are encouraged, particularly those which also involve the detailed application of materials parameters to problems in engineering structures, components and design. In addition to the area of materials engineering, the interacting fields of mechanical, manufacturing, aeronautical, civil, chemical, corrosion and design engineering are considered relevant. Activity should be directed at analysing engineering failures and carrying out research to help reduce the incidences of failures and to extend the operating horizons of engineering materials. Emphasis is placed on the mechanical properties of materials and their behaviour when influenced by structure, process and environment. Metallic, polymeric, ceramic and natural materials are all included and the application of these materials to real engineering situations should be emphasised. The use of a case-study based approach is also encouraged. Engineering Failure Analysis provides essential reference material and critical feedback into the design process thereby contributing to the prevention of engineering failures in the future. All submissions will be subject to peer review from leading experts in the field.