An Investigation on the Premature Failure of Spur Gear in Coal Stacker Reclaimer: Mechanical Properties and Microstructure Analysis
Keywords:Spur Gear, Premature Failure, AISI 4340, Stacker and Reclaimer
In this paper, the premature failure of the spur gear on the coal stacker reclaimer system is reported. Fault failure that occurs in the driving spur gear which is made from AISI 4340 steel with respect to the composition of nickel, carbon, chromium, mangan and molybdenum. The spur gear has been operating for about three years when several teeth failed. A tooth in the driving gear is failed where a part of a tooth is separated and torn from its main gear body. An integrity evaluation of this driving spur gear including visual examination, photo documentation, chemical analysis, hardness measurement, metallographic examination and also a tensile strength test. The failure zone is examined by an electron microscope equipped with EDX facilities. Premature failure is associated with porosities present inside the gear bodies which propagate and torn a gear tooth. The hardness around the failed tooth also increase based on the Rockwell Hardness Test. The gear actually able to receive the designed load on the coal stacker and reclaimer based on the yield strength which around 834.73 MPa and the maximum tensile strength is around 921.39 MPa.
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