Root cause failure analysis of a tracked vehicle balance arm.

This paper relates to an upgraded Industrial tracked vehicle which was found with a failed Balance arm during disassembly. The failure analysis of an actual Balance Arms surface was carried out using Fractography and Non Destructive testing techniques to dig out the root cause. The analysis revealed microscopic signatures categorically pointing towards post failure surface mechanical damage. The factor causing to promote failure was improper manufacturing i.e. casting which was further attributed to MnS inclusions.N/

Effect of geometrical parameters of aluminum-to-steel bolted connections

Abstract : Through experimental and numerical studies, this research work aims to provide directions on the optimal geometric configuration for single-lap and double-lap bolted connection between aluminum alloy 6061-T6 and steel. From experimental test results, the effects of different geometric parameters on the joint strength were discussed. These parameters include the end-distance, the side-distance, the pitch-distance, the plate thickness and the joint eccentricity. Then, the experimental results were compared to predicted results using design references and geometric recommendations proposed by design references were critically examined. The experimental study was complemented by finite element (FE) analysis to extend the study to a larger range of parameters. In addition to the analysis of the geometric parameters listed above, the effects of the gage-distance on the joint strength were studied in the FE analysis. The experimental and finite element results show that a careful selection of geometric parameters can result in the high improvement of the connection strength and failure mode. Limiting the side-distance to the minimum recommended value was found to limit the strength of a connection with two bolts in a column to that of the one-bolt connection. In most cases, bearing was found to govern the strength of the connections. The calculated bearing strengths were found to underestimate significantly the connection strength. Based on these analyses, maximum geometric parameters beyond which there is no further increase of the joint capacity were evaluated and optimum geometric parameters were proposed

FEM simulation of welded joint geometry influence on fatigue crack growth resistance

Fatigue behaviour of welded joints is investigated, in terms of welded joint geometry and the fatigue crack position. It is based on previous work which involved numerical simulation of fatigue crack growth in a welded joint made of micro-alloyed, low-carbon pressure vessel steel P460NL1, with the main focus on fatigue crack growth rate through different welded joint regions. The goal here was to change the size of the heat affected zone, as the region in which the fatigue crack initiated, and to compare the results obtained for new crack length values with the original ones, obtained by creating numerical models based on experimental data. A number of models were created, some of which simulated the case with a bigger heat affected zone (and, consequently, a smaller crack length in the weld metal), and other which simulated the case with a smaller heat affected zone. Due to the micro-structural differences between these two welded joint regions, noticeable differences appeared in the numbers of cycles obtained for each zone with varying fatigue crack lengths, as well as in the total number of cycles for both zones through which the crack propagated