Failure Analysis and Repair of a Broken Extruder Shaft

##plugins.themes.bootstrap3.article.main##

  •   Salem Ali Karrab

  •   Mohamed Ali Ballem

Abstract

In this paper a failure analysis of a screw shaft used in a co-rotating intermeshing twin-screw extruder was carried out; furthermore a detailed description for the repair procedure of the fractured part was presented. By means of the preliminary analyses of the failed shaft which includes a visual examination, appearance of fracture face, and photographic documentation of the fractured surfaces, and by summarizing and analyzing all relevant data it was possible to determine that the combination of torsion and bending forces was the cause of the failure. The shaft fractured with evidences of fatigue failure. Repairing of the fractured shaft was mainly performed by welding technique followed by suitable heat treatments and appropriate inspection methods. After repair process is completed, the extruder was put back into service, the recorded data during the trial and regular operations were satisfactory and within the design limits. Finally, in order to avoid future accidents and to prevent such problems in similar equipment, precautionary measures and recommendations were proposed.


Keywords: Bending, Failure, Fatigue, Torsion, Twin-Screw Extruder, Welding

References

H. F. Giles Jr, E. M. Mount III, and J. R. Wagner Jr, Extrusion: the definitive processing guide and handbook: William Andrew, 2004.

R. G. Hill, "4 - Polymers," in Biomaterials, Artificial Organs and Tissue Engineering, L. L. Hench and J. R. Jones, Eds., ed: Woodhead Publishing, 2005, pp. 37-47.

E. M. Mount, "15 - Extrusion Processes," in Applied Plastics Engineering Handbook, M. Kutz, Ed., ed Oxford: William Andrew Publishing, 2011, pp. 227-266.

D. V. Rosato, D. V. Rosato, and M. V. Rosato, "5 - EXTRUSION," in Plastic Product Material and Process Selection Handbook, D. V. Rosato, et al., Eds., ed Oxford: Elsevier, 2004, pp. 227-281.

T. Sakai, "Screw extrusion technology - Past, present and future," Polimery, vol. 58, pp. 847-857, 2013.

C. Rauwendaal, Polymer Extrusion: Carl Hanser Verlag GmbH & Company KG, 2014.

K. Kohlgrüber, Co-rotating Twin-screw Extruders: Fundamentals, Technology, and Applications: Carl Hanser Publishers, Munich, 2008.

A. Shrivastava, "5 - Plastics Processing," in Introduction to Plastics Engineering, A. Shrivastava, Ed., ed: William Andrew Publishing, 2018, pp. 143-177.

A. J. Tremaine, "Twin-screw extrusion of commodity grade dairy ingredients to ingredients to produce value-added products," M.S. thesis, University of Minnesota Digital Conservancy. http://hdl.handle.net/11299/131156 2012.

K. Kohlgrüber, Co-Rotating Twin-Screw Extruder: Carl Hanser Verlag GmbH & Company KG, 2012.

J. R. Wagner, E. M. Mount, and H. F. Giles, "11 - Twin Screw Extruder Equipment," in Extrusion (Second Edition), J. R. Wagner, et al., Eds., ed Oxford: William Andrew Publishing, 2014, pp. 125-148.

P. Andersen, R. Kanarski, and J. R. Wagner, "Troubleshooting the Co-rotating Fully Intermeshing Twin-screw Compounding System," in Handbook of Troubleshooting Plastics Processes, ed, 2012.

J. A. Allan, "The Development of Libyan Industry," in Libya Since Independence (RLE Economy of Middle East), ed: Routledge, 2014, pp. 67-84.

Failure Analysis and Prevention: ASM International, 2002.

A. H. Committee, Properties and Selection: Irons, Steels, and High-Performance Alloys: ASM International, 1990.

S. Shawki, "Early Failure of High Pressure Screw Pumps: Shaft Fracture," Journal of Failure Analysis and Prevention, vol. 13, pp. 595-600, 2013/10/01 2013.

N. W. Sachs, "Understanding the surface features of fatigue fractures: how they describe the failure cause and the failure history," Journal of Failure Analysis and Prevention, vol. 5, pp. 11-15, 2005.

T. Brown, "Torsional Fatigue Failures, Identification, Diagnosis and Prevention," Uptime Mag, pp. 20-2, 2014.

D. J. Wulpi, Understanding how components fail: ASM international, 2013.

J. L. González-Velázquez, Fractography and Failure Analysis: Springer, 2018.

K. Mills, J. R. Davis, J. Destefani, and D. Dieterich, ASM Handbook, Volume 12-Fractography: ASM International Materials Park, OH, 1987.

F. Berndt and A. van Bennekom, "Pump shaft failures — a compendium of case studies," Engineering Failure Analysis, vol. 8, pp. 135-144, 2001/04/01/ 2001.

(2011, 2020-01-15). Coperion: Preventive wear diagnosis guarantees constant product quality [News, Article]. Available: https://plasticker.de/Plastics_News_13427_Coperion_Preventive_wear_diagnosis_guarantees_constant_product_quality.

Downloads

Download data is not yet available.

##plugins.themes.bootstrap3.article.details##

How to Cite
[1]
Karrab, S. and Ballem, M. 2020. Failure Analysis and Repair of a Broken Extruder Shaft. European Journal of Engineering and Technology Research. 5, 1 (Jan. 2020), 107-111. DOI:https://doi.org/10.24018/ejers.2020.5.1.1738.