Failure analysis and redesign of a wagon wheel shaft for sugar cane transport

Abstract

In this study, a failure analysis of the wheel shafts of wagons for transporting sugar cane is carried out. Several shafts have broken with a small fatigue propagation zone and a large sudden-fracture zone. The material and load condition of the shafts were examined. Stress measurements on a vehicle with a similar suspension system were conducted to fi nd the dynamic loads and calculate the impact factor. An impact factor higher than the one reported in the literature was found. According the manufactures, AISI 1045 steel was the material of the shaft; however, it was found that the material of some shafts did not have the specifi cations of AISI 1045 steel. Moreover, even if the shafts were made with good quality AISI 1045 steel, the stresses are so high that the element will fail due to fatigue. Finally, some recommendations are given to increase the reliability of the shafts, and a new design and manufacturing process are proposed