Abstract
On 22 pieces of broken centrifugal cast rolls the cause of breakage is studied. Then it has been concluded that a fatigue crack is initiated at casting defects or inclusions, corrosion occurs at casting defects and this part acts as an origin of fatigue cracking. Forged suction roll has no such defects although one breakage and two cracking troubles were experienced. The origin of fatigue cracking is studied in case of the forged suction rolls by the fractography and stress analysis of the FEM. A crack on the axial direction is created by a shortage of wall thickness which was designed wrong. A crack on the circumferential direction is created by a combination of stress concentration at the irregularly narrow drilled portion and maximum stress shifting based on wrong maintenance.
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