Engineering Failure Analysis 13 (2006) 3243

www.elsevier.com/locate/engfailanal

Cracks in a powder vibrating sieve disc

Osman ASI_ *

Department of Mechanical Engineering, Usak Engineering Faculty, Afyon Kocatepe University, Usak, Turkey

Received 3 December 2004; accepted 10 December 2004

Available online 31 March 2005

Abstract

A case study of cracks in a powder vibrating sieve disc is presented in this paper. An evaluation of the failed disc was
undertaken to assess its integrity that included a visual examination, photo documentation, chemical analysis, micro-
hardness measurement, tensile testing, and metallographic examination. The fracture surfaces were examined with the
help of a scanning electron microscope equipped with energy-dispersive X-ray (EDX) facility. In addition, the deposits
scraped from the inner surface of the bolt holes were subjected to X-ray diraction. Spectrum analysis and EDX results
identied the material of the disc as zinc-coated (galvanized) silicon-killed structural steel. Results indicate that cracks
initiated from bolt holes in the disc and propagated in a peripheral direction and a radial direction with dierent
lengths. The cracks are fretting fatigue cracks from high vibration stress. The reason why cracks initiated at holes is
that there were fretting wear scars the inner surface of the bolt holes.
2005 Elsevier Ltd. All rights reserved.

Keywords: Fretting fatigue; Bolted joint; Surface coatings; Vibration; Failure analysis

1. Introduction

Powder vibrating sieves are designed and constructed to separate non-organic aggregate solid products
having dierent particle size. These machines are usually installed on machine lines in industrial environ-
ments. The inow and outow of the product is made possible through machines positioned upstream
and downstream from the vibrating sieve. The separation is made possible by the vibrations imported
by the vibrating unit.
Fig. 1 shows the general appearance of the failed disc belonging to the powder vibrating sieve. The failed
disc, 8 mm thick and 1200 mm in diameter, is fastened to a small disc by ten steel bolts, M10 with 8.8 metric

*
Tel.: +90 276 2634195; fax: +90 276 2634196.
E-mail address: osmanasi@hotmail.com.

1350-6307/$ - see front matter 2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.engfailanal.2004.12.034
 O. ASI_ / Engineering Failure Analysis 13 (2006) 3243 33

Fig. 1. General appearance of the failed disc.

grade. Both the failed disc and the small disc are connected to the vibrating unit by bolts. Fig. 2 shows the
installation of the disc in powder vibrating sieve which has technical features of 0.73 kW electrical power,
12,750 N centrifugal force and 1390 rpm. The system is excited by a transverse vibration. The disc was
assembled 5 months ago and kept in normal environmental conditions at ceramic machine lines. Cracks
were found in powder vibrating sieve disc at fastened regions with the small disc, in service. In this disc,
cracks initiated from bolt holes and propagated in a peripheral and a radial direction with dierent lengths,
as shown in Fig. 3.

Fig. 2. The installation of the disc.

34 O. ASI_ / Engineering Failure Analysis 13 (2006) 3243

Fig. 3. Appearance of cracks.

Bolted joints are commonly used in assemblies due to the advantages they oer, such as the ability to
develop a clamping force and the ease of disassembly for maintenance and repair. However, the presence
of bolt holes induces high stress concentrations, which are hence recognized to be a source of damage devel-
oped during fatigue loading. Stress distributions around the bolt hole in a mechanical joint depends primar-
ily on the geometry of the bolted plates, loading conditions, material anisotropy, bolt-hole clearance, bolt
stiness and the friction between the bolt and the plates. Friction and clearance between the bolt and the
hole aect the most signicantly the distribution and magnitude of the stress around the bolt hole. In fa-
tigue loading, damage around bolt holes consists of two types. These are hole wear and damage at the con-
tact surface of the plates. The hole wear is caused by the erosion of material around the bolt hole as a result
of friction forces. The deformation of the bolt hole in the plate signicantly inuences the stiness and
strength of mechanically fastened joints. Permanent deformation of the hole results in looseness in the joint,
which can result in signicant strength reduction, especially during cyclic loading. Damage at the contact
surface is induced by bolt bending under loading.
Bolted machine parts that are subjected to vibration are the most susceptible to fretting [1]. Fretting is a
special wear process that occurs at the contact area between two materials under loads and subject to slight
relative movement by vibration or some other forces [2]. If the relative movement is the consequence of a
cyclic loading of one or both the contacting components, fretting will act conjointly with the cyclic stress,
and the fatigue strength of the component will be much reduced. This phenomenon is referred to as fretting
fatigue. Fretting fatigue is one of the most important phenomena for inducing a signicant reduction of fa-
tigue strength and consequently, leading to unexpected failure accidents of the engineering structures even at
very low stresses. The fatigue limit in fretting fatigue reduces to a range from a half to one-third of the fatigue
limit in plain fatigue without fretting [3]. There are more than fty factors that inuence the fretting fatigue
behaviour, including the contact pressure, amplitude of relative slip, mean stress, contact material, surface
condition, frequencies of alternating stress and slip, etc. [4]. The fretting process may cause local metal loss
and impact the initiation and/or propagation of fatigue cracks. There are some features of fretting-fatigue
crackings that are unique [5]. Fretting fatigue usually results in recognizable damage to at least one of the
contacting surfaces. The fretted areas are roughened and, in steel, are usually decorated reddish-brown
 O. ASI_ / Engineering Failure Analysis 13 (2006) 3243 35

deposits. Cracks may be initiated in damaged region but are located close to the boundary between the dam-
aged areas. The initiation of fatigue cracks in fretted regions depends mainly on the state of stress in the sur-
face, particularly stresses caused by high friction. In fretting fatigue, frictional stress on the contact surface
combined with repeated stress cause damage which leads to the initiation and propagation of fatigue cracks.
Small fatigue cracks are initiated early in life and some grow to be propagating cracks. Cracks grow to a
given depth by tangential stress combined with repeated stress and then propagate with repeated stress alone
[6]. After formation due to fretting, cracks propagates initially under shear (mode II) conditions under the
inuence of the near surface shear stress eld due to friction of fretting [2].
The aim of the present work is to investigate the results of a failure analysis of a powder vibrating sieve
disc used in a ceramic machine lines.

2. Experimental procedure

The failed disc was inspected visually and macroscopically; care was taken to avoid damage of fractured
surfaces. The failed disc was subjected to optical microscopy, photo documentation, chemical analysis and
micro-hardness measurement both at the failure zone and away from the failure zone. The fracture surfaces
were ultrasonically cleaned and examined with the help of a scanning electron microscope (SEM) equipped
with energy-dispersive X-ray (EDX) facility. In addition, the deposits scraped from the inner surface of the
bolt holes were subjected to X-ray diraction. Conventional tensile tests carried out on specimens machined
from failed disc.

3. Results and discussion

Chemical analysis using atomic absorption spectrophotometry was carried out and the results are given
in Table 1 along with the specied chemical composition. Spectrum analysis and EDX results identied the
material of the disc as zinc-coated (galvanized) silicon-killed structural steel. The chemical composition of
the failed disc was found to be similar to ASTM A36 steel. The actual chemical composition shows silicon
content on the high side. However, the slight dierence in silicon content is unlikely to inuence the per-
formance of the galvanized parts to a signicant extent [7].
Galvanizing is one of the major methods used to apply zinc-based coatings on steel in order to provide
sacricial protection against corrosion. The chemical composition of the steel is very important to the quality
of the galvanized coating since a metallurgical reaction between the zinc and the iron is occurring. Diculties

Table 1
Chemical composition of the failed disc and ASTM A36 steel
Element Failed disc ASTM A36 (individual values are maximums)
%C 0.23 0.25
%Si 0.019 0.40 (deoxidation, Si killed)
%Mn 0.976 0.81.2
%Ni 0.021
%Cr 0.028
%Mo 0.011
%S 0.01 0.05
%P 0.014 0.04
%Cu 0.017 0.2 (when specied)
%Al 0.039
36 O. ASI_ / Engineering Failure Analysis 13 (2006) 3243

arise during galvanizing of Si-containing steels; the enhanced reactivity of steel in the presence of Si under
typical galvanizing conditions results in very thick and brittle coatings with unacceptable appearance. In or-
der to avoid the adverse eects of silicon on the galvanized coating, silicon content in the steel should be
killed [79].
Tensile samples were cut from the edge of the disc hub to determine its hardness, tensile strength, yield
strength, and elongation. The results are listed in Table 2 and show that the mechanical properties met the
technical demands.
Visual inspection of the failed disc showed that there were severe damaged regions at 1# and 9# bolt
holes, and cracks initiated from mentioned bolt holes and propagated in a peripheral direction and a radial
direction with dierent lengths, as shown in Figs. 3 and 4. Also, it was observed that a crack initiated in the
vicinity of the 10# bolt hole and propagated in a radial direction. All cracks become through-thickness
crack. The peripheral direction cracks propagated from a bolt hole towards other bolt hole, occurred from
7# bolt hole to 3# bolt hole (Fig. 3). The lengths of radial direction cracks were smaller than the lengths of
peripheral direction cracks. It is thought that the crack propagation rate in the peripheral direction was
faster than that in radial direction. Fig. 4 shows the radial cracks growing at on angle of approximately
4560 to the surface-damaged areas.
There were some corrosion spots observed on the local bolt hole surfaces. The inner surfaces of the 1#
bolt holes were rough and fretting wear scars existed, as shown in Fig. 5. Similar extensive damage was also
observed in the other bolt holes.

Table 2
Mechanical properties of the failed disc and ASTM A36 steel
Material Tensile strength (MPa) Yield strength (MPa) Elongation (%) Hardness (HV)
Failed disc 480 245 23 145
ASTM A36 400550 220250 23 120180

Fig. 4. Appearance of crack propagations from bolt holes.

 O. ASI_ / Engineering Failure Analysis 13 (2006) 3243 37

Fig. 5. Photograph of the cross section of the fretted bolt hole.

Light optical metallographic analysis was carried out on the failed disc. Samples for optical microscopy
were prepared by grinding and polishing, and were etched in 2% Nital. The microstructure consist of ferrit
and pearlit matrix (Fig. 6(a)). This is typical of low carbon steel. The failed disc was zinc-coated (galva-
nized) as shown in Fig. 6(b). The zinc lms were about 30 lm thick. The micro hardness value measured
at the surface of the coating was 80 HV0.05.
Fig. 7 shows the inner surface of the bolt hole, which was severely gouged from rubbing between the bolt
and the bolt hole surface, thus oering many sites for crack initiation. Note the inner surface of the bolt
hole indicative of the fretting damage zone leading to crack initiation sites. In severe damaged areas where
all the coating had been removed were decorated with reddish-brown deposits which is a characteristic
product of fretting damage on steel parts. The X-ray diraction analysis carried out on these deposits indi-
cated them to be iron oxides. Fig. 8 shows a typical macro-fracture appearance after separation. The frac-
ture surfaces are roughened. The fracture surfaces of the failed disc show characteristic of fretting fatigue.
Multiple crack initiation sites could be seen from Fig. 8.
Small surface fretting wear scars were found on the wall of the bolt hole. Fig. 9 exhibit the reason why
cracks initiated at bolt holes is that there were fretting wear scars. Failure occurred from initiated cracks
under the fretting wear scars. Fretting wear scars showed localized areas of heavy damage, where all the
coating had been removed. Fretting virtually always causes recognizable surface damage to at least one
of the faying surfaces. The damage sites often serve as crack-initiation regions, and the local stress concen-
trations that would normally act as fatigue-cracking initiation sites may not be involved in the cracking
process [2]. Surface cracks could be observed which looked like they had the potential to be major fatigue
cracks. Fig. 9 also shows cracks located the centre of the fretting wear scars. Cracks were generated by the
frictional stresses at the fretting contact [6].
Scanning electron microscopic (SEM) examination of the failed disc surfaces revealed roughness, micro-
cracks, and pits in the surface-damaged regions. These features have been associated with fretting damage.
Fig. 10 shows that a number of cracks initiated within the fretted zones. Deformation lines were found at
the fracture surface near the fracture origins, as shown in Fig. 10. Fatigue striations and small dimples were
found with tearing lines and secondary cracks. Fatigue striations could be seen in the propagation zone
with secondary cracks and dimples. The undamaged surface was relatively smooth and clean. Fig. 11 also
shows crack initiation regions and adhesive wear areas. Crack initiation occurred at the limit of fretting-
damaged areas. The fretting damage sites often serve as crack-initiation regions.
From the above observations, it is clear that cracks initiated from fretting damage, which is the main
reason why the crack initiated during service. The cause of the fretting, in this case, was believed to be from
self-loosening of the bolts. There were no indications in the sieve records, or in the memories of the chief
engineers of the factory, that these bolts had ever been retightened after initial installation. It has been
widely observed that fasteners turn loose when subjected to dynamic loads in the form of shock or vibra-
38 O. ASI_ / Engineering Failure Analysis 13 (2006) 3243

Fig. 6. Microstructure of the disc showing (a) a mixture of ferrite and pearlite, pearlite forms in bands due to manganese segregation
and prior hot working, (b) the Zn coated surface.

tion. This reduces the clamping force and leads to joint failure. Self-loosing is the most frequent cause of
failure of dynamically loaded bolted connections [10]. Fretting also occurs due to inadequate bolt
tightening.
There are several factors that inuence the self-loosening process. Transverse or shear loading (perpen-
dicular to the fastener axis) is the most severe form of loading for vibration-induced loosening, and that loos-
ing results from gross slip at the head and thread interfaces [10]. When a bolted joint is subjected to cyclic
shear load, localized slip occurring at the contact surfaces can accumulate over the loading cycles and cause
loosening slip over the entire contact. The most apparent factor that contributes to slip is an applied shear
force. The shear force is transferred from the clamped component to the fastener through friction between
the head-bearing surface and the clamped component, and possibly due to contact between the fastener and
surface of the hole in the clamped component. The shear force acting at the fastener head also develops a
bending moment on the fastener. An important feature of slip in fasteners is that it is inuenced by clearances
that determine the state of side contact between the fastener and the sides of the clamped component hole.
 O. ASI_ / Engineering Failure Analysis 13 (2006) 3243 39

Fig. 7. SEM micrograph of fretting damage surface.

Fig. 8. SEM micrograph showing the multiple crack initiations sites (see black arrow).

The nal factor that contributes in overcoming the friction force is the elastic deformation at the contact
surfaces. The resulting elastic deformation at the contact surfaces tends to cause slip.
When the bolt joint is subjected to transverse excitation, impact forces also occur between the bolt and
bolt hole of the plate. Impact can cause simultaneous slip at the threads and the bolt head. The bolt bends
due to the impact force. Bolt bending and bolt head slip cause side contact between bolt shank and bolt
hole boundary [10]. Impacts also play a critical role in bolt self-loosening. Relative motion between the bolt
head and clamped part dominates the self-loosening process.
Fretting wear occurs from repeated shear stresses that are generated by friction during small amplitude
oscillatory motion or sliding between two surfaces pressed together in intimate contact. The oscillatory
40 O. ASI_ / Engineering Failure Analysis 13 (2006) 3243

Fig. 9. SEM micrograph showing fretting wear scars containing crack the inner surface of the bolt holes.

motion responsible for fretting can be induced by system vibrations or by cyclic loading of one of the
components. Surface cracks initiate in the fretting wear region. The relative slip amplitude is typically less
than 50 lm and displacements as small as 10
4 lm have produced fretting [2].
In bolted joints, fretting fatigue cracks are normally initiated under a combination of local shear stress,
produced by the frictional forces between the rubbing surfaces, plus long-range cyclic stresses in the com-
ponent. Those shear stresses are vital to cracking initiation. The shear stresses promote relative slip. Crack
nucleation due to fretting must involve a stress concentration or discontinuity [6].
Knowledge of the stress distributions around the bolt hole is also a basic requisite for prediction of
failure. Due to the load transfer and bolt bending, the bolts create contact forces on the hole surfaces.
Under load, the lateral compression of the bolt results in a relative slip and a high contact pressure. Fric-
tion and bolt-hole clearance signicantly aect both the distribution and magnitude of the stresses
around the hole. It is usually assumed that the radial stress distribution on the hole boundary varying
as a cosine function. A cosine distribution is to assume a certain contact pressure distribution acting
 O. ASI_ / Engineering Failure Analysis 13 (2006) 3243 41

Fig. 10. SEM micrograph of the crack zone in the failed disc. Deformation lines (slip) at the surface near initiation zone (indicated by
arrows).

Fig. 11. SEM micrograph showing characteristic at fretted damage zone.

on the boundary of loaded holes [11]. The bolt-hole contact angle is illustrated in Fig. 12. Since bolt-hole
contact region is close to the high tensile stresses, the conjunction of high stresses and friction damage
locates crack initiation there [12].
On the hole boundary, the maximum radial stress appears at B, and the maximum peripheral stress ap-
pears at A, as shown in Fig. 12. Usually, the stresses at A and B are 23 times higher than those without
holes [13], and this can make the stresses exceed the yield limit of the material, and lead to local plastic
deformation and stress redistribution.
42 O. ASI_ / Engineering Failure Analysis 13 (2006) 3243

Fig. 12. Sites of maximum stresses at hole and contact angle for bolt-hole loading in disc.

Usually, a crack cannot initiate around a hole boundary during a short time with a reasonable
design. But if there are coarse machining marks, impact forces, fretting wear scars, not only can
this lead to a high stress concentration, but can also cause fatigue crack initiation during a short
service time. When the local stress exceeds the material yield strength, it is possible to form a fa-
tigue crack.
The radial stress and peripheral stress are produced by centrifugal stress. If a hole is in a disc zone where
the radial stress is higher than the peripheral stress, the crack will propagate in the bb 0 section (Fig. 12). If
a hole is in a disc zone where the radial stress is lower than the peripheral stress, the crack will propagate in
the aa 0 section [13]. The main cracks in the disc initiated from bolt boles then propagated bb 0 section.
This indicates that cracks initiate under radial stress.

4. Conclusion

1. Spectrum analysis and EDX results identied the material of the disc as zinc-coated silicon-killed struc-
tural steel. Mechanical properties and the chemical composition of the failed disc were found to be sim-
ilar to ASTM A36 steel.
2. Cracks initiated from bolt holes in the disc and propagated in a peripheral direction and a radial direc-
tion with dierent lengths.
3. Cracks initiated around the hole boundary because of fretting damage. The cause of the fretting was
believed to be from self-loosening of the bolts under transverse vibration.
4. The cracks are fretting fatigue cracks from high vibration stress around the bolt hole.

5. Recommendations

1. Fretting can be prevented by using high-strength fasteners properly tensioned to prevent relative motion
of contacting surface.
2. The tightness of the clamping bolts should be veried regularly.
 O. ASI_ / Engineering Failure Analysis 13 (2006) 3243 43

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