Analyzing the Failure of a Truck's Rear Axle Shaft Requires a Thorough Investigation to Pinpoint the Root Cause of the Issue

Abstract

The analysis of a failed rear axle shaft from a dumper truck involved a comprehensive investigation to ascertain the underlying cause of the failure. Visual inspection, material analysis, mechanical testing, and fracture analysis were conducted to assess the condition of the axle shaft. The axle shaft exhibited signs of fatigue failure, with the fracture surface showing fatigue striations. Microstructural analysis revealed a coarse grain structure with inclusions, indicating potential material defects. Tensile testing showed that the axle shaft had lower-than-expected mechanical properties, suggesting a possible issue with material quality or heat treatment. Based on the analysis, the root cause of the failure was determined to be a combination of material defects and fatigue loading. Types of investigation like as visual examination, chemical analysis, hardness test, tensile test, fractography and ultrasonic test, and microstructure examination. Microstructure observation of the sample indicates a normal ferrite–pearlite (lower critical point) sorbite-type structure with some spheronization seen on some portions Results indicate that the failure occurred due to a sudden load on the axle shaft, specifically at its weakest point. The shear stresses on the axle shaft were insufficient to withstand the stresses caused by the sudden loading. Based on the analysis, make recommendations for corrective actions to prevent similar failures in the future. This may include design improvements, material changes, maintenance procedures, or operational changes. This may include design improvement, material changes, maintenance procedures, and operational changes. Implement the recommended corrective actions to prevent similar failures in other axle shafts or similar components.