Stress Analysis of Final Drive Pinion Shaft of Electric Shovel Through The Use of FEM

Abstract

           In this research failure analysis of final pinion shaft is analyzed in detail. After visual investigation of the fracture surface it is indicated that fracture occurred due to torsional-bending fatigue. Fatigue crack has initiated at the fillet shoulder. When considering power transmission systems, bending and torques acting on the shaft are determined; stresses occurring at the failure surface are calculated. Stress analysis is also carried out by using finite element method (FEM) and the results are compared with the calculated values. Endurance limit and fatigue safety factor is evaluated, fatigue cycle analysis of the shaft is estimated. Reason for failure is investigated and it can be concluded that fracture occurred due to faulty design or manufacturing of the fillet shoulder (low radius of curvature at shoulder). In conclusion, effect of change in radius of curvature on stress distribution is explained by using FEM