Failure Analysis and Fatigue Life Estimation of a Shaft of a Rotary Draw Bending Machine

Human consumption of the Earth's resources increases the need for a sustainable development as an important ecological, social, and economic theme. Re-engineering of machine tools, in terms of design and failure analysis, is defined as steps performed on an obsolete machine to return it to a new machine with the warranty that matches the customer requirement. To understand the future fatigue behavior of the used machine components, it is important to investigate the possible causes of machine parts failure through design, surface, and material inspections. In this study, the failure modes of the shaft of the rotary draw bending machine are inspected. Furthermore, stress and deflection analysis of the shaft subjected to combined torsion and bending loads are carried out by an analytical method and compared with a finite element analysis method. The theoretical fatigue strength, correction factors, and fatigue life sustained by the shaft before damaged are estimated by creating a stress-cycle (S-N) diagram. In conclusion, it is seen that the shaft can work in the second life, but it needs some surface treatments to increase the reliability and fatigue life.

• B. Engel
• Sara Salman Hassan Al-Maeeni

• Failure analysis
• fatigue life
• FEM analysis
• shaft
• stress analysis.

[1] S. Gujaran, and S. Gholap, “Fatigue analysis of drive shaft,” International Journal of Research in Aeronautical and Mechanical Engineering, Vol. 2, Issue. 10, P. 22-28, 2014.
[2] M. G. Deepan Marudachalam, K. Kanthavel, and R. Krishnaraj, “Optimization of shaft design under fatigue loading using Goodman method,” International Journal of Scientific & Engineering Research, Vol. 2, Issue. 8, ISSN 2229-5518, 2011.
[3] S. P. Raut, and L. P. Raut, “Failure analysis and redesign of shaft of overhead crane,” International Journal of Engineering Research and Applications, Vol. 4, Issue. 6, P. 130–135, 2014.
[4] H. A. Kadam, and N. S. Hyalij, “Design and analysis of belt conveyor roller shaft,” International Journal of Engineering Trends and Technology (IJETT), Vol. 36, Number 1, 2016.
[5] L. N. Robert, “Machine design an integrated approach,” Pearson Prentice Hall Publishers, USA, ISBN: 0-13-017706-7, 2006, P. 558-560
[6] D. K. Padhal, and D. B. Meshram, “Analysis and failure improvement of shaft of gear motor in CRM shop,” International Journal of Engineering and Science, Vol. 3, Issue. 4, P. 17-24, 2013.
[7] F. Casanova, “Failure analysis and redesign of a wagon wheel shaft for sugar cane transport,” Dyna, Vol. 78, Issue. 166, P. 48-54, 2011.
[8] D. Crivelli, R. Ghelichi, and M. Guagliano, “Failure analysis of a shaft of a car lift system,” Procedia Engineering 10, 2011, P. 3683–3691.
[9] J. Jamshidi, A. R. Mileham, and G. W. Owen, “Dimensional tolerance approximation for reverse engineering applications,” International design conference, Dubrovnik - Croatia, May 2006, P. 855–862.