Abstract
Increasing industrial demand for new products including advanced production technology leads to substantial natural resources consumption. Furthermore, huge environmental pollution and emerging environmental legislation motivate the machine tools industry as one of the major resource consumers on a global scale to develop methods for more sustainable use of the Earth's resources. Machine tools re-engineering concerning design and failure analysis is an approach by which outdated machines are upgraded and restored to like-new machines. To evaluate the mechanical failure of the used machine components and to ensure their reliable future performance, it is essential to make material, design, and surface investigations. In this paper, an experimental approach based on the principle of a three-point bending test is presented to evaluate the shaft elastic behavior under loading. Moreover, finite element analysis and numerical integration method are used to determine the maximum linear deflection and bending stress of the shaft. Subsequently, a comparison between the results is made. In conclusion, it was found that the measured bending deflection and stress were well close to the admissible design values. Therefore, the shaft can be used again in the second life cycle. However, based on previous surface tests conducted, the shaft surface needs re-carburizing and refining treatments to ensure the reliable performance of the surface.
Highlights
According to DIN 8586, rotary draw bending (RDB) is a forming process used for producing tubes with precise bending radii and wall thickness by the creation of a bending moment using RDB machines
Maximum linear deflection and bending stress under a load of 25785 N were calculated by using numerical integration method and compared with the values acquired from finite element analysis (FEA) method by using Abaqus software
At the end of this research and based on the reliable performance of the shaft in comparison to the design requirements, a decision was made to reuse the shaft in the second life cycle after applying some recommended surface treatments based on the results of the surface tests conducted previously [1]
Summary
According to DIN 8586, rotary draw bending (RDB) is a forming process used for producing tubes with precise bending radii and wall thickness by the creation of a bending moment using RDB machines. Three-point bending method is proposed in ASTM D790, ISO 178 It is a method specifies the mechanical behavior of the test sample subjected to a vertical load applied to its longitudinal axis at the midpoint between two supports [4,5,6]. The span length selection depends on the depth of a rectangular cross-section or the diameter of a circular cross-section of the test specimen This testing method provides a reasonable estimation about the bending stress-strain response of the shaft material to a real load without destructing the shaft.
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