Ijert Ijert: Fatigue Failure Analysis of Marine Engine Crankshaft
Ijert Ijert: Fatigue Failure Analysis of Marine Engine Crankshaft
ISSN: 2278-0181
Vol. 2 Issue 6, June - 2013
Vijaykumar Chalwa 22 Asst Professor & dean of R&D, Department of Mechanical Engineering,
SMSMPITR, Akluj-413118, Maharashtra, India
Pappu Gaikwad 3
3
Asst Professor S B Zadbuke Polytechnic, Barshi, Maharashtra, India
Abstract
A case study of a catastrophic failure of a web marine crankshaft and a failure Analysis under bending
and torsion applied to crankshafts are presented. A microscopy (eye seen) observation showed that the crack
initiation started on the fillet of the crankpin by rotary bending and the propagation was a combination of cycle
bending and steady torsion. The crack front profile approximately adopts a semi-elliptical shape with some
istortion due to torsion and this study is supported by a previous research work already published by the
authors. The number of cycles from crack initiation to final failure of his crankshaft was achieved by recording
of the main engine operation on board, taking into account the beach marks left on the fatigue crack surface.
The cycles calculated by the linear fracture mechanics approaches showed that the propagation was fast which
means that the level of bending stress was relatively high when compared with total cycles of an engine in
service. Microstructure defects or inclusion were not observed which can conclude that the failure was
probably originated by an external cause and not due to an intrinsic latent defect. Possible effects of added
torsional vibrations which induce stresses are also discussed. Some causes are analyzed and reported here but
the origin of the fatigue fracture was not clearly determined.
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Keywords: crankshaft failure, rotating bending, steady torsion, fatigue crack growth
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Many examples of fatigue crack growth under mode I 2. Main Engine crankshaft
loading have shown that Linear Elastic Fracture
Mechanics (LEFM) theory is increasingly being
applied to the practical engineering problems,
including material selection, design and analysis of
engineering structures. It is a tool that can
approximate the stresses surrounding a fracture to
better explain damage occurrences, and is used when
a defect, often a crack or corrosive attack, should be
evaluated with regards to allowable dimensions. By
altering the determined model parameters, the analyst
can estimate the magnitude of the mechanical stress
applied to a component at the time of failure.
These measurements are made at regular crank angles alignment is to measure static web deflections, see
and historical limits have been defined, which relate Figure 1. Deflection measurements at each crank web
observed deflation values to crack stress levels are until now an empirical process to assess and
associated with once per revolution bending stresses. control the misalignment of crankshafts. Indeed this
The effects of dynamic loads have largely been is a static and not a dynamic measurement. As a
ignored. These loads, resulting from inertia and gas consequence of rotating bending and torsion
forces will add to the stress field generated by the generally also appear dynamic forces which can
static misalignment. Furthermore, the location of the induce torsional or axial vibrations on crankshafts.
rotating shaft in the bearing will affect the estimate of Several observed catastrophic failures have shown
stress field based on the static web deflation that the crack initiation generally starts closed to the
measurements. web crankpin where the stress bending is higher.
These measurements are made at regular crank angles
The vibrations are generally ignored for and historical limits have been defined, which relate
failure analysis but, indeed, they have an important observed deflection values to crack stress levels
role. Torsional vibration is the speed change of a associated with once per revolution bending stresses.
rotating shaft within one rotating period. An engine
crankshaft itself is deflecting (rotationally) forward However the effects of dynamic loads have
and backward while it is operating, like a balance of a largely been ignored but are also of the significant
block. A crankshaft, like a plain torsion-bar, has mass importance. In spite of the industry use of the
and a torsional spring rate which causes the deflection measurements as a Condition assessment
crankshaft system to have its own torsional resonant tool, this measurement is less than satisfactory. It is
frequency. The torque peaks and valleys of the difficult and uncomfortable to take and indeed
variation loading cause the engine crankshaft itself to doesn’t reflect operating conditions of load or
deflect (rotationally) forward and backward, and temperature. Cracks caused by bending generally
when those pulses (excitations) are near the start at the crankpin fillet and progress diagonally
crankshaft resonance frequency, they can cause the across. Sometimes abnormal bending forces are
crank to vibrate uncontrollably and eventually can generated by main-bearing bore misalignment,
lead to breaking. During the engine operation are also improperly fitted bearings, loose main-bearing caps,
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induced resonant axial and torsional vibrations (is the unbalanced pulleys, or over tightened belts. The
speed change of a rotating shaft within one rotating distribution of cracks caused by torsional (or
period) which can also contribute to an eventually twisting) forces is the same as for bending forces. All
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catastrophic crankshaft failure. A vibration damper crankshafts have a natural period of torsional
(absorber) can avoid such damages for protecting the vibration which is influenced by the length/diameter
engine. Therefore a torsional vibration measurement ratio of the crank, the overlap between crankpins and
will made and will install a flywheel and a vibration main journals, as well as the material used
damper accordingly. If the damper was not adequate
(measuring torsional vibrations allows determinations 3. Experimental Procedure
of the proper damping required) or the regular
maintenance was not done, crankshaft damage can
occur during its normal expected crankshaft life. A 3.1 Material and chemical composition
vibration damper in poor conditions will have a
reduced performance and high torsional stresses can The crankshaft damaged was assembled in a main
occurs in the crankshaft. engine container ship, with controllable pitch
propeller, diameter 3800 mm and 4 blades. The
crankshaft material: 42 CrMo 4 + Ni + V (chemical
2.1Deflection measurement
composition, %: C=0.39; Si=0.27; Mn=0.79;
P=0.015; S=.014; Cr=1.14; Mo=0.21; Ni=0.45;
V=0.10); ReH=590 MPa and Rm=780 MPa;
HB=285; grain flow forged, quenching and tempered.
Main engine: 8 cylinders in line; 4-stroke; fire order:
1-3- 5-7-8-6-4-2. Rated power: 3520 kW, 600 rpm;
crankshaft diameters: 280 mm (crankpin) and 300
mm (main journal). Counter weights: 12; flexible
coupling and damper. Equipped with a reduction
Figure 4 – Crank web deflection measurement gearbox (ip =0.2683).
4. Results
4.2 Fractographic features and visual bending and the crack propagation was by rotating
inspection bending combined with torsion. The cause of failure
will be analyzed in the following.
Figure 11 – The Vickers hardening in the first information about the number of cycles to failure
millimeters from surface between the crack initiation and the catastrophic
failure.
The material closed the crack initiation was
analyzed at the laboratory and shown a bainitic On board there is on board book a record of the each
structure, Figure 10 and the hardness Vickers was voyage (all events and time in hours from starting
about 285, Figure 11, which is according to the until stopping the main engine). The history of
standard values for this type of steel and delivered by fatigue crack growth is written on the fatigue failure
the manufactory and confirmed by the class surface through the so called beach marks or arrest
certificate. lines. It is not possible to know how many fatigue
cycles were done during the crack nucleation process
and in the first millimeters after nucleation as well,
5.2 Micro-Fractography but statistically a value of 80 to 90% of total life is
spent in the crack nucleation process.
Looking at the initiation site with good
lighting and magnification, revels no inclusions,
precracks, or other abnormal stress raisers. One
5.3 Fatigue crack growth analysis and
should conclude as a first impression that the damage prediction of fatigue life
was caused by a latent defect of the material.
However, the experience has shown that a crankshaft The stress calculation and the number of
after an operation time of more than 32,000 hours at cycles to failure were obtained using the fracture
600 rpm, more than 1,15x10^9 cycles such a flaw can mechanics approaches and compared with the cycles
by no means have the causative factor of the damage, obtained from the record on board. The Stress
and therefore a crankshaft has long proved its Intensity Factors used for the equation of Paris law
endurance strength. were obtained from another previous work [4, 5]. The
calculations were carried out into two stages: first,
The fatigue surface after the region where the remote stress level was calculated taking into
the crack (or cracks) began presents not a flat surface account the length of crack growth between beach
but an oblique surface is within 2 to 3 mm depth from marks and the records on board. Second, the number
of cycles obtained from the final fracture until a 5.4 Failure analysis discussion
certain crack depth considered as the start of crack
growth after crack initiation was calculated. The fatigue fracture appears in two distinct
surfaces: a smooth almost to perpendicular to the
The number of cycles to failure of this crankshaft and a second one in a horizontal plane
crankshaft was achieved by recording of the main with the crankshaft, with transition zones between
engine operation on board, taking into account the two surfaces, according to Figure 8. This confirms a
beach marks left on the fatigue crack surface. typical fracture by fatigue, characterized by
Through the beach marks (stopping or starting of the propagation with a crack front profile approximately
machine) left on the fatigue crack surface, observed elliptical from the crack initiation point until the fast
on Figure 12 it is possible obtain a correlation final fracture. The beach marks show several stops of
between a certain crack length and the time spent the main engine which permits to obtain the history
during the corresponding voyage of the ship. Using of the fatigue crack growth Process associated to the
the crack growth equation which gives the number of vessel voyages. A fracture surface configuration
cycles by integrating the Paris Law for a considered perpendicular to the crankpin axis is generally
crack length, it is possible to estimate the applied associated to the loading bending in shafts. However
remote stress (∆σ) for R=-1 (reversed bending). a helical surface observed in this fracture clear shows
a mixed-mode fatigue, i.e., a combination of rotating
bending with steady torsion, and found in the
literature [4, 5]. Consulting the main engine book on
board, it is possible identify the beach mark zones of
the fatigue fracture with the last voyages of the vessel
(visited ports), starting from the fast fracture
(catastrophic failure) towards the crack initiation
point. The total estimated hours found were about
2400, computed from the catastrophic failure until
the crack region of the nucleation. It is not possible to
know the number of cycles of the nucleation process,
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