Engineering Failure Analysis
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1 Engineering Failure Analysis Dr Matt Rudas +61 (0)
2 Mechsafe Engineering - Overview Formed in 2016 in Perth, Western Australia Specialising in: Advanced failure analysis Advanced fatigue design and analysis Reliability, availability & maintainability analysis Engineering critical & fitness-for-service assessments Strain gauging and condition monitoring Cathodic protection and corrosion analysis General design / verification / simulation Mechsafe Engineering - Engineering for Safe Life 2
3 Mechsafe Engineering - Overview Matt Rudas background MPhil WIT/University of Swansea (UK) - fracture of FRP composites PhD - University of Western Australia - crack propagation in metal-ceramic composites Fatigue design, failure analysis, stress analysis, strain gauging Two Australian design patents (international patents pending) Strong background in both finite and boundary element techniques Image source: aerospaceengineeringblog.com Mechsafe Engineering - Engineering for Safe Life 3
4 Mechsafe Engineering - Overview Mechsafe Engineering - Engineering for Safe Life 4
5 Mechsafe Engineering - Overview Gas turbine blade fatigue failure Railway bridge fatigue failure Rotating machinery fatigue failure Gear tooth failure Shaft fretting fatigue failure Rolling contact fatigue failure Rail head check fatigue failure Image source: eurailscout.com Mechsafe Engineering - Engineering for Safe Life 5
6 Engineering Failure Analysis Component Failure Analysis (CFA) Considers physical influences such as loads, material properties, environment Identifies failure mechanism Root Cause Investigation (RCI) Increases the detail of a CFA Considers human factors Root Cause Analysis (RCA) Causal factor charting Considers management systems Interested in causes over which there is control Image source: leica-microsystems.com Mechsafe Engineering - Engineering for Safe Life 6
7 Component Failure Modes Fatigue (44% - Reliability Center, Inc.) Poor design Incorrect operation Incorrect assembly/installation Change in operating parameters Corrosion Wear / maintenance failure Manufacturing Heat treatment Image source: reliasoft.com Mechsafe Engineering - Engineering for Safe Life 7
8 Component Failure Modes Overload Plastic collapse Instability (buckling) Serviceability Vibration Deflection Image source: shellbuckling.com Mechsafe Engineering - Engineering for Safe Life 8
9 Fatigue Failure Fatigue failure Initiation Welded vs cast/machined/forged S-N / e-n Propagation/brittle fracture Crack growth laws e.g. Paris, Forman Linear elastic fracture mechanics Ductile brittle transition Mechsafe Engineering - Engineering for Safe Life 9
10 Fatigue Failure Accurate analysis requires accurate inputs: Loads/stresses Strain gauges Pressure transducers for hydraulics Numerical analysis Material properties MDR s Hardness testing Metallurgical analysis Fracture parameters Stress intensity factors Mechsafe Engineering - Engineering for Safe Life 10
11 Fatigue Failure Fracture parameters are difficult to determine AS Pressure equipment - In-service inspection Simplified fracture mechanics and corrosion assessments BS Guide to Methods For Assessing the Acceptability of Flaws in Metallic Structures Failure analysis, acceptance criteria, life extension, justification of deviations from a design code Numerical analysis Mechsafe Engineering - Engineering for Safe Life 11
12 Numerical Analysis Unlike codes, not restricted by: Simplistic geometric assumptions e.g. flat plates, tubes/pipes Crack propagation always straight/planar Simplistic assumptions regarding the loads Changing stress fields during crack propagation Rotating principal stress directions Numerical analysis avoids the conservatism required by the assumptions made using hand calculations Mechsafe Engineering - Engineering for Safe Life 12
13 Numerical Analysis Mechsafe staff have been using BEASY for 20+ years Boundary element based DBEM crack modelling Non-linear contact and crack face loads Automatic crack growth As the crack grows, K values along the crack front and the fatigue growth law determine the new crack front shape Cracks can grow round corners and change shape as determined by the geometry and loading Any crack shapes can be added to a crack library Mechsafe Engineering - Engineering for Safe Life 13
14 Model Configuration Mechsafe Engineering - Engineering for Safe Life 14
15 Flaw Definition - Library Mechsafe Engineering - Engineering for Safe Life 15
16 User defined cracks can be added to the crack library if required This process uses a mesh of the required crack along with some additional crack front & breakout edge data Flaw Definition - User Defined Mechsafe Engineering - Engineering for Safe Life 16
17 NASGRO material property database is in software User defined values can be added to the model Tabulated da/dn (crack growth rate) data can be used Material Properties Mechsafe Engineering - Engineering for Safe Life 17
18 Images courtesy BEASY UK Non-planar Flaw Fracture Assessment Mechsafe Engineering - Engineering for Safe Life 18
19 Automatic Crack Propagation Images courtesy BEASY UK Mechsafe Engineering - Engineering for Safe Life 19
20 Fretting Fatigue Contact with Crack Growth Images courtesy BEASY UK Mechsafe Engineering - Engineering for Safe Life 20
21 Post Processing Tools Images courtesy BEASY UK Mechsafe Engineering - Engineering for Safe Life 21
22 Produces a map of critical crack sizes Threshold for crack growth Critical size for fracture BEASY Defect Scanner Images courtesy BEASY UK Mechsafe Engineering - Engineering for Safe Life 22
23 Damage Tolerance & Design of Repairs All techniques discussed here can provide the following information growth rates of cracks time to reach the critical size a new value of operational load to slow crack growth to an allowable rate a new value of operational load to stop any crack growth at all the effectiveness of repair methods that don t completely eliminate the presence of the cracks a sensitivity study of the effect of errors in the measurement of the crack size using NDT, if different NDT methods are giving different results inspection intervals and locations Mechsafe Engineering - Engineering for Safe Life 23
24 Summary Equipment failure, unnecessary maintenance shuts and badly designed repairs can cost operators large sums These costs can be avoided by the application of predictive assessments Modern numerical techniques and software enhances fracture mechanics assessments, and makes them more affordable The information that these assessments provide is essential for critical asset management and maintenance strategy considerations, resulting in cost savings, less equipment downtime and accident prevention Mechsafe Engineering - Engineering for Safe Life 24
21 Fracture and Fatigue Revision
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