Failure analysis of a high-speed shaft in a reducer used to drive a diaphragm pump has been carried out. The shaft fractured in the keyway. Theoretical calculation, chemical analysis, micro-structural characterization, and finite element simulation were used for the analysis to determine the failure reasons and bring improved measures. The result shows that the chemical composition of materials, microstructure, and mechanical properties of the shaft and key meet the requirement; however, the improper design of the key and shaft causes stress concentration in the keyway, and the end of the keyway tends to crack. The fit between shaft and gear and the fit between key and shaft are too loose that they can cause fretting, which make the cracks to expand. In addition, several improved designs have been suggested and they prove to be effective after simulating.
High-speed shaft Keyway Finite element analysis Fretting Stress concentration
This is a preview of subscription content, log in to check access
This work was supported financially by the National Natural Science Foundation of PR China through Grant 51275035.
R.J. Shipley, W.T. Becker, Analysis and Prevention ASM Handbook, vol. 11 (American Society for Metals, Metals Park, 1996)Google Scholar
F. Berndt, A. Van Bennekom, Pump shaft failures—a compendium of case studies. Eng. Fail. Anal. 8(2), 135–144 (2001)CrossRefGoogle Scholar
M.E. Stevenson, J.L. McDougall, R.D. Bowman et al., Failure analysis of a high-speed pinion shaft. J. Fail. Anal. Prev. 5(2), 48–54 (2005)CrossRefGoogle Scholar
S.F. Hassan, M.R. Alam, Failure analysis of gearbox and clutch shaft from a marine engine. J. Fail. Anal. Prev. 10(5), 393–398 (2010)CrossRefGoogle Scholar
W. Muhammad, K.M. Deen, Failure analysis of water pump shaft. J. Fail. Anal. Prev. 10(2), 161–166 (2010)CrossRefGoogle Scholar
X.Q. Hou, Y. Li, C.K. Liu et al., Fracture failure analysis of a 30CrMnSiA steel shaft. J. Fail. Anal. Prev. 12(5), 485–489 (2012)CrossRefGoogle Scholar
A. Göksenli, I.B. Eryürek, Failure analysis of an elevator drive shaft. Eng. Fail. Anal. 16(4), 1011–1019 (2009)CrossRefGoogle Scholar
G. Atxaga, A.M. Irisarri, Failure analysis of the end of a shaft of an engine. Eng. Fail. Anal. 17(4), 714–721 (2010)CrossRefGoogle Scholar
H.S. Han, Analysis of fatigue failure on the keyway of the reduction gear input shaft connecting a diesel engine caused by torsional vibration. Eng. Fail. Anal. 44, 285–298 (2014)CrossRefGoogle Scholar
O.A. Zambrano, J.J. Coronado, S.A. Rodríguez, Failure analysis of a bridge crane shaft. Case Stud. Eng. Fail. Anal. 2(1), 25–32 (2014)CrossRefGoogle Scholar
N. Parida, S. Tarafder, S.K. Das et al., Failure analysis of coal pulverizer mill shaft. Eng. Fail. Anal. 10(6), 733–744 (2003)CrossRefGoogle Scholar