Abstract: 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.
Abstract: Rotary draw bending is a method which is being used
in tube forming. In the tube bending process, the neutral axis moves
towards the inner arc and the wall thickness distribution changes for
tube’s cross section. Thinning takes place in the outer arc of the tube
(extrados) due to the stretching of the material, whereas thickening
occurs in the inner arc of the tube (intrados) due to the comparison of
the material. The calculations of the wall thickness distribution,
neutral axis shifting, and strain distribution have not been accurate
enough, so far. The previous model (the geometrical model)
describes the neutral axis shifting and wall thickness distribution. The
geometrical of the tube, bending radius and bending angle are
considered in the geometrical model, while the influence of the
material properties of the tube forming are ignored. The advanced
model is a modification of the previous model using material
properties that depends on the correction factor. The correction factor
is a purely empirically determined factor. The advanced model was
compared with the Finite element simulation (FE simulation) using a
different bending factor (Bf =bending radius/ diameter of the tube),
wall thickness (Wf = diameter of the tube/ wall thickness), and
material properties (strain hardening exponent). Finite element model
of rotary draw bending has been performed in PAM-TUBE program
(version: 2012). Results from the advanced model resemble the FE
simulation and the experimental test.