Failure Analysis Methods in Industrial and Systems Engineering

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University of Florida *

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3246

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Mechanical Engineering

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Apr 3, 2024

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1 | P a g e F a i l u r e a n a l y s i s m e t h o d s i n M e c h E n g i n e e r i n g Failure Analysis Methods in Industrial and Systems Engineering ENC3246 University of Florida 10.14.2022

2 | P a g e F a i l u r e a n a l y s i s m e t h o d s i n M e c h E n g i n e e r i n g Failure analysis methods in Mech Engineering I. Common Types of failures in Mechanical engineering .............................................................. 3 A. Types of failures .............................................................................................................................. 3 B. Cause of failure ................................................................................................................................ 5 II. Failure Analysis methods ............................................................................................................. 6 C. Preventative methods ..................................................................................................................... 6 1) Destructive and non-destructive methods ........................................................................................ 6 D. Forensic methods ............................................................................................................................. 7 1) Destructive and non-destructive ...................................................................................................... 7 2) Standards in mechanical engineering ............................................................................................... 7 III. Case Study ...................................................................................................................................... 8 E. Description ..................................................................................................................................... 8 F. Investigation .................................................................................................................................... 8 G. Recommendations ......................................................................................................................... 10 IV. References .................................................................................................................................... 11

3 | P a g e F a i l u r e a n a l y s i s m e t h o d s i n M e c h E n g i n e e r i n g I. Common Types of failures in Mechanical engineering Mechanical engineering is a branch of engineering specialized in processing energy forms and translate it into any desired motion. Engineers in this area perform from the general to the most specific tasks. Going through the design, manufacture and testing processes of devices that alter, transform, and use energy to create any type of motion.[1] Mechanical engineers are constantly exposed to failures in their products, which they try to predict and evade through, dynamics, statics, and mechanic of materials analysis. Although, currently through simulations with CAD programs, failures can be easier predicted and before the production and testing phase. A. Types of failures Mechanical engineers often find failures in their mechanical systems. Much of what is taught in engineering school needs to be put in practice. To maximize the accuracy of these devices, engineers must understand the basics of mechanics of mechanic materials, statics, and dynamics. They must be aware of the definitions and features of stress, deformation, slip, fracture, tension, and compression.[1] Which lead us to the four mechanical failures: Erosion, corrosion, Fatigue, and overload.[6] Mechanisms are commonly exposed to erosion, which implies a set of material removal through a series of impacts from a substance independent from the mechanism. Even while each collision only removes a tiny amount of material, the overall damage is frequently substantial. If you employ particles with sharp edges, erosion can get worse.[7] The effect might not be apparent until it is too late if the degraded surface is an internal surface that is not visible. In the worst-case scenario, a hole has already developed. Erosion is a common and dangerous failure that is exhaustingly analyzed by mechanical engineering. But, not considered by materials engineers in the design phase of a device.

4 | P a g e F a i l u r e a n a l y s i s m e t h o d s i n M e c h E n g i n e e r i n g Figure 1: Motor piece facing erosion Chemicals, take an important field of study on engineers, chemical compounds can create all types of reactions. Every surface of metallic constructions is vulnerable to corrosion. resulting from electrochemical or chemical processes.[3] While general attack corrosion is a known and foreseeable issue, it can also result in metal failure. Depending on the conditions under which the metal is being corroded, there are many ways to avoid corrosion. Techniques for preventing corrosion are: Environmental Modifications, Metal selection and surface conditions, Cathodic protection, Coating, Plating, corrosion inhibitors Mechanical engineers also face mechanic fatigue; a deficiency that happens when an item is put under recurrent or fluctuating loading but never reaches a level high enough to result in failure in a specific application and become an overload. Fatigue occurs when mechanisms are exposed to tensions, compressions or other type of external forces acting on them during prolonged times. A crack, which could have existed in the material when it was created or could have formed over time because of cyclic deformation around stress concentrations, is always the first sign of fatigue failure.

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