IMPROVING MACHINERY RELIABILITY
AN INTRODUCTION TO FAILURE ANALYSIS THE CAUSES OF FAILURES ROOT CAUSE ANALYSIS (RCA) AND UNDERSTANDING THE ROOTS PHYSICAL ROOTS HUMAN ROOTS INDUSTRIAL ACTIVITIES GENERAL HUMAN ERROR THE HUMAN ERROR STUDY LATENT ROOTS HOW THE MULTIPLE ROOTS INTERACT WHY MULTIPLE ROOTS ARE FREQUENTLY MISSED THE BENE?TS AND SAVINGS USING LOGIC TREES SUMMARY CHAPTER SOME GENERAL CONSIDERATIONS ON FAILURE ANALYSIS THE FAILURE MECHANISMS — HOW THEY OCCUR AND THEIR APPEARANCES WHEN SHOULD A FAILURE ANALYSIS BE CONDUCTED AND HOW DEEPLY SHOULD IT GO? HOW LONG SHOULD IT LAST? DIAGNOSING THE FAILURE FINDING THE PHYSICAL ROOTS INTRODUCTION TO MATERIALS — STRESSES AND STRAINS DETERMINING THE FAILURE MECHANISMS THE PLANT FAILURE ANALYSIS LABORATORY MATERIALS AND THE SOURCES OF STRESSES STRESS ELASTICITY PLASTICITY MODULUS OF ELASTICITY (YOUNG’S MODULUS) TOUGHNESS FATIGUE FATIGUE STRENGTH VS TIME SOME BASIC METALLURGY CARBON STEELS IRON AND ITS ALLOYING ELEMENTS AISI NUMBERING CODE PLAIN CARBON STEEL — THE BASICS UNDERSTANDING STEEL TERMINOLOGY AND MATERIAL DESIGNATIONS CAST IRON STAINLESS STEELS STRENGTHENING METALS HEAT TREATING COLD WORKING THERMAL EXPANSION OVERLOAD FAILURES INTRODUCTION TEMPERATURE EFFECTS ON OVERLOAD FAILURES ANALYSIS OF DUCTILE FAILURES ANALYSIS OF BRITTLE FRACTURES CHEVRON MARKS UNUSUAL CONDITIONS BRITTLE FRACTURES OF DUCTILE MATERIALS RAPID FORCE APPLICATION CONSTRAINED MATERIALS NOTCH SENSITIVITY OF BRITTLE MATERIALS FATIGUE FAILURES (PART 1): THE BASICS FATIGUE FAILURE CATEGORIES STRESS CONCENTRATIONS STRUCTURE CHANGES CAUSED BY HIGH-CYCLE FATIGUE DIAGNOSING A HIGH-CYCLE-FATIGUE FAILURE PROGRESSION MARK BASICS FRACTURE GROWTH AND UNDERSTANDING THE SOURCE OF THE STRESS — ROTATING BENDING VS PLANE BENDING PROGRESSION MARKS AND VARYING STRESS LEVELS PROGRESSION MARKS AND STRESS CONCENTRATIONS RATCHET MARKS ROTATING-BENDING FAILURES WITH MULTIPLE ORIGINS DISTINGUISHING BETWEEN THE EFFECTS FROM STRESS AND STRESS CONCENTRATIONS FRACTURE FACE CONTOUR AND STRESS CONCENTRATIONS INTERPRETING THE INSTANTANEOUS ZONE SHAPE GUIDES TO INTERPRETING THE FATIGUE FRACTURE FACE SOLVING A FAILURE FATIGUE (PART 2): TORSIONAL, LOW-CYCLE, AND VERY-LOW-CYCLE FAILURE IN?UENCES AND FATIGUE INTERPRETATIONS TORSIONAL FATIGUE LOADS RIVER MARKS AND FATIGUE CRACK GROWTH PLATE AND RECTANGULAR FAILURES FATIGUE DATA RELIABILITY AND CORROSION EFFECT ON FATIGUE STRENGTH RESIDUAL STRESS COMBINED FATIGUE AND STEADY STATE STRESSES BASE MATERIAL PROBLEMS VERY-LOW-CYCLE AND LOW-CYCLE FATIGUE VERY-LOW-CYCLE IN RELATIVELY BRITTLE MATERIALS VLC IN DUCTILE MATERIALS UNUSUAL SITUATIONS FAILURE EXAMPLES EXAMPLE 6 15: DIAGNOSIS AND RECOMMENDATION EXAMPLE 6 16: INSPECTION CONCLUSIONS AND RECOMMENDATIONS EXAMPLE 6 17: INSPECTION EXAMPLE 6 18: INSPECTION EXAMPLE 6 20: INSPECTION UNDERSTANDING AND RECOGNIZING CORROSION CORROSION RATES PH EFFECTS EFFECT OF AVAILABLE OXYGEN EXPOSURE TIME AND FLOW EFFECTS TEMPERATURE EFFECTS THE EFFECT OF CONTAMINANTS EIGHT TYPES OF CORROSION — RECOGNITION AND PREVENTION UNIFORM CORROSION APPEARANCE COMMENTS ON UNIFORM CORROSION PREVENTION FRETTING GALVANIC CORROSION COMMENTS SELECTIVE LEACHING INTERGRANULAR CORROSION EROSION-CORROSION CAVITATION CONCENTRATION CELL CORROSION CREVICE CORROSION PITTING CORROSION STRESS-CORROSION CRACKING (SCC) PREVENTION AND CORRECTION HYDROGEN DAMAGE HYDROGEN BLISTERING HYDROGEN-IN?UENCED CRACKING (HIC) AND ALSO CALLED HYDROGEN-INDUCED CRACKING HYDROGEN EMBRITTLEMENT A SPECIAL CATEGORY: MICROBIOLOGICALLY IN?UENCED CORROSION (MIC) LUBRICATION AND WEAR THREE TYPES OF LUBRICATED CONTACTS LAMBDA: THE LUBRICANT FILM THICKNESS BASIC BEARING LUBRICATION ELASTOHYDRODYNAMIC HYDRODYNAMIC ACTION BOUNDARY LUBRICATION MANUFACTURING A LUBRICANT VISCOSITY MEASUREMENT AND VISCOSITY INDEX VISCOSITY INDEX ADDITIVES GREASES LUBRICANT FUNCTIONS ROLLING ELEMENT BEARINGS THE PRESSURE–VISCOSITY COEF?CIENT LUBRICANT FILMS AND THE EFFECTS OF CONTAMINATION PLAIN BEARINGS DE?NING WEAR ADHESVIE WEAR ABRASIVE WEAR EROSION SUMMARY COMMENTS ON WEAR FAILURES BELT DRIVES BELT DESIGN BELT DRIVE DESIGN AND LIFE BELT OPERATION DRIVE EF?CIENCIES BELT OPERATION AND FAILURE CAUSES SLIPPAGE HIGH AMBIENT OPERATING TEMPERATURES HIGH OPERATING LOADS MISALIGNMENT SHEAVE AND SPROCKET WEAR BELT RESONANCE BELT DRIVE FAILURE ANALYSIS PROCEDURES CHAPTER 10 BALL AND ROLLER BEARINGS BEARING MATERIALS PARTS OF A BEARING CAGES BEARING RATINGS AND EQUIPMENT DESIGN HERTZIAN FATIGUE, ROLLING ELEMENT BEARING LUBRICATION, AND SURFACE FATIGUE THE REASONS BEARINGS FAIL A DETAILED ROLLING ELEMENT BEARING FAILURE ANALYSIS PROCEDURE STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 APPEARANCE OF ELECTRICAL DAMAGE MECHANISMS STEP 6 STEP 7 STEP 8 STEP 9 FOR BALL BEARINGS FOR ROLLER BEARINGS ROLLER AND TAPERED ROLLER BEARING MOUNTING SURFACES CHAPTER 11 GEARS GEAR TERMINOLOGY TYPES OF GEARS TOOTH ACTION LOAD AND STRESS FLUCTUATIONS GEAR MATERIALS TOOTH CONTACT PATTERNS BACKLASH DESIGN LIFE AND DETERIORATION MECHANISMS THROUGH-HARDENED GEAR DETERIORATION MECHANISMS PITTING AND WEAR PLASTIC DEFORMATION ADHESIVE WEAR CASE-HARDENED GEAR DETERIORATION MECHANISMS MICROPITTING RIPPLING PITTING SPALLING CASE CRUSHING ANALYZING GEAR FAILURES INTERMEDIATE PINION INSPECTION BROKEN GEAR TOOTH LARGE PUMP DRIVE GEAR HAUL TRUCK PINION PAPER MACHINE REDUCER GEAR KILN REDUCER INTERMEDIATE GEAR INBOARD–OUTBOARD PROPELLER DRIVE GEAR CHAPTER 12 FASTENER AND BOLTED JOINT FAILURES HOW BOLTS WORK BOLT STANDARDS NUT STANDARDS MATERIALS FATIGUE DESIGN ASSEMBLY PRACTICES BOLTING PATTERNS AND SEQUENCES FASTENER FAILURES FATIGUE FAILURES HYDROGEN EMBRITTLEMENT AND HYDROGEN-IN?UENCED CRACKING (HIC) FAILURE LOCATIONS AND BOLT DESIGNS GENERAL COMMENTS AND CAUTIONS ON BOLTING EXAMPLE 12 E1 DIAGNOSIS AND RECOMMENDATION EXAMPLE 12 E2 EXAMPLE 12 E3 EXAMPLE 12 E4 DIAGNOSIS AND RECOMMENDATIONS EXAMPLE 12 E5 EXAMPLE 12 E6 EXAMPLE 12 E7 EXAMPLE 12 E8 CHAPTER 13 A BRIEF REVIEW OF MISCELLANEOUS MACHINE ELEMENT FAILURES CHAINS CHAIN DESIGN LUBRICATION WEAR CHAIN BREAKAGE LIP SEALS FAILURE ANALYSIS FLEXIBLE COUPLINGS BIBLIOGRAPHY FOR PRACTICAL PLANT FAILURE ANALYSIS