Scribd
Upload
102 views30 pages

Fundamental Theories of Damages/Failure

The document discusses various modes of failure in machinery components and their causes. It defines failure and lists common modes as overload, buckling, impact, fatigue, corrosion-influenced fatigue, corrosion, and wear. The most frequent causes of failure are identified as misalignment, unbalance, resonance, bearings, looseness, and flow-related problems. Misalignment and unbalance are noted as the most significant causes, often resulting from faults introduced during assembly, manufacturing, or operation. Other potential failure sources discussed include electrical, bent shafts, and gear meshing issues.

Uploaded by

Milion duguma
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
102 views30 pages

Fundamental Theories of Damages/Failure

The document discusses various modes of failure in machinery components and their causes. It defines failure and lists common modes as overload, buckling, impact, fatigue, corrosion-influenced fatigue, corrosion, and wear. The most frequent causes of failure are identified as misalignment, unbalance, resonance, bearings, looseness, and flow-related problems. Misalignment and unbalance are noted as the most significant causes, often resulting from faults introduced during assembly, manufacturing, or operation. Other potential failure sources discussed include electrical, bent shafts, and gear meshing issues.

Uploaded by

Milion duguma
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 30

CHAPTER 2

Fundamental Theories
of Damages/Failure
Brainstorming

a)What is failure ?

b)Why failure ?

c)How failure ?
Failure
Failure can be defined as any change in a machinery part or
component which causes it to be unable to perform its intended
function satisfactorily.
Failure can be also defined, in general, as an event that does not
accomplish its intended purpose .
 Failure of a material component is the loss of ability to function
normally.
 Components of a system can fail one of many ways, for example
excessive deformation, fracture, corrosion, burning-out, degradation of
specific properties (thermal, electrical, or magnetic), etc.
Mode of Failures

– Different analysts use different systems, but the most practical way for
plant people to categorize failures is by
o Overload
o Buckling
o Impact
o Fatigue
o corrosion-influenced fatigue
o corrosion and
o wear.
Conti…

 Overload: Applying a single load causes the part to deform or fracture as the load is applied.
 Stress exceed failure stress
 Wrong selection of material
 Inaccuracy in design
 Improper use of material
 Material flows /defect
 Change to environment
 Buckling : compressive stress in structural member
 Long ‘slender ‘ members
 Unstable /sideway deflection
 Bending stress is exceed failure stress
 Impact :the striking of one body against another
 Object is colliding with component
 Material toughness exceeded (J/m2)
 Often unpredictable (Force ,Velocity, Area)
 Component collide with object
 Wear: A variety of mechanisms result in loss of material by mechanical
removal
 Erosion : surface to surface contact
 Pitting and scuffing
Causes of Failure in Machinery

Failure of components, especially, structural members and machine elements can


lead to heavy loss of lives, wealth and even may jeopardize the society!

 Causes for failure include: improper materials selection, improper processing,


inadequate design, misuse of a component, and improper maintenance.

 It’s the engineer’s responsibility to anticipate and prepare for possible failure; and
in the event of failure, to assess its cause and then take preventive measures.
Conti…
 Familiar stages preceding final failure are “incipient failure,” “incipient
damage,” “distress,” “deterioration,” and “damage,” all of which eventually
make the part or component unreliable or unsafe for continued use.
 Meaningful classifications of failure causes are:
1. Faulty design.
2. Material defects.
3. Processing and manufacturing deficiencies.
4. Assembly or installation defects.
5. Off-design or unintended service conditions.
6. Maintenance deficiencies (neglect, procedures).
7. Improper operation.
Conti…
 Many causes of failure in machinery exist and their predominance will vary to some
degree from industry to industry However, the most common causes, are:
Misalignment
 Unbalance
 Resonance
 Bearings
 Looseness
 Flow-related problems
 Electrical
 Bent Shaft
 Gear Mesh
Conti…
It may be argued that Bearing failure is the most common cause but
it is appropriate to look at the root cause for the bearing failure and
work with that.
Accordingly, the most common causes, in order, are
 misalignment
 unbalance
 and bearings.
Most of these faults show characteristics that are identifiable with
vibration analysis. Others may show better through oil analysis or
thermography.
Misalignment


Misalignment is universally recognized as the leading contributor to
machinery failure. For the same level of vibration it is much more
serious than unbalance for its effect in reducing bearing life, largely
because of the parasitic axial thrust.


Misalignment exists when the center lines of two adjacent machines
deviate from each other.
Alignment related problems include soft foot, pipe strain, inadequate
bases etc.
Conti…
Principal Causes of Misalignment

 Lack of appropriate Standards and Specifications


 Poor Tolerances and Poor Methods
 Good Methods, but bad practices

 Lack of understanding of precision process


Dynamic movement (thermal growth, pipe strain etc.)
 Mis-diagnosis with Unbalance or Looseness
Unbalance

Unbalance is arguably the next most significant


contributor to premature machine failure.

Unbalance exists when the mass center line of a rotor is


not coincident with the geometric center line. The
resultant orbital motion has a severe impact on the life of
bearings and on seals.
Conti…
Principal Causes of Unbalance

 Accumulation of assembly tolerances


 Poor attention to assembly
 Inappropriate use of standards
 Non-homogeneous materials (casting blow holes)
 Operational – uneven build up of product
 Erosion of rotor material
Resonance
Resonance is a condition which occurs when a machine forcing
frequency (related to rotational speed) becomes coincident with, or close
to, the natural frequency of a machine component or appendage.

The problem is most often seen in the supporting structure or attached


pipe work.

 The condition is like that of a mechanical amplifier and can result in a very severe
vibration at that frequency when the forcing vibration is already too high.
Bearing Failure
– Bearing failure itself is not a significant source of vibration until
quite advanced stages of failure are reached. However, with
appropriate signal conditioning the information relating to the early
stages of failure is available in the vibration signal.

– The most common cause of bearing failure is probably loss or


contamination of the lubricant. However, assuming lubrication is
adequate, mechanical defects such as misalignment and
unbalance have a severe impact upon bearing life.
Conti…
Looseness
Looseness may be considered as being where parts are not fitted
tightly together. Typically this fits. Into three categories;
1. Structural looseness/weakness of machine feet, base plate or
foundation. Also by deteriorated grouting, loose hold-down bolts at the
base and distortion of the frame or base. This may be seen as Soft Foot.
2. Loose Plummer block bolts, cracks in frame structure or bearing
pedestal.
3. Improper fit between component parts, e.g. excessive clearance in a
sleeve or rolling element bearing, impeller loose on its shaft .
Flow Related Problems
– Flow related problems such as cavitation and recirculation are
caused by pumps operating outside of their design parameters.

– When a centrifugal pump is operated below its design capacity, or


with extreme suction conditions, it is likely to experience
cavitation. Cavitation occurs when vapor bubbles are formed in the
pump low pressure regions and then collapse in a higher pressure
region; the collapse leads to erosion of the impeller, and
sometimes the casing.
Conti…
– Another common problem with centrifugal pumps is recirculation.
Liquid returns from the impeller discharge either externally to the
impeller suction through worn wear rings, or may return internally,
and impacts on the impeller vanes. The problem is worse when the
discharge is throttled or when the impeller is axially displaced so
that it does not align with the pump discharge. The result is
increased vibration at vane passing frequency and there may be a
significant temperature increase. The reverse flow in the pump
and mixing of the liquid results in a random vibration not unlike
cavitation and can lead to erosion of the impeller.
Electrical Problems
– Electrical problems which can result in vibration include;
 Uneven air gap
 Cracked or broken rotor bars

 Eccentric rotors
 Loose phase connections
Bent Shaft
– Another potential source of machine vibration is a bent shaft.
– Shafts may become bent by being subject to :
 an excessive force from unbalance,
seizure or thermal distortion.
This may also occur through poor assembly from
cocked bearings,
 incorrectly torqued Taper Lock bushings, or
tapered distance pieces.
Gear Meshing
– When faults occur in gearboxes they will often express as
vibrations related to gear meshing frequency. These faults may
include;

 Misalignment of the gearbox internally or externally


 Poorly manufactured gears
 Bent shaft
What causes most of the problems
?
30

THANKS

You might also like