Torsion fatigue failure of bus drive shafts |
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Authors: | D H Duffner |
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Affiliation: | (1) Principia Engineering Services, San Francisco, CA. |
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Abstract: | The mystery surrounding high failure rates in the drive shafts of a large municipal transit agency's fleet of 40 newly acquired
articulated buses is investigated. The drive shafts were fabricated from a low-carbon (0.45%) steel such as AISI 5046. An
examination of the drive shafts on all 40 buses is conducted, and 6 different drive shaft designs are identified among the
fleet, but all of the failures, 14 in all, are limited to just one of the identified designs. Microscopic examination of the
fracture surface of one of the failed drive shafts under a scanning electron microscope is conducted to determine the failure
mode. Evidence of high-cycle fatigue is found, and a finite-element analysis is conducted to compare the maximum stress of
the design exhibiting failures with the most common of the other designs that exhibits no failures. A fatigue life prediction
is performed to determine just how much longer the expected fatigue life of the surviving design is compared to the design
that suffered the early failures. |
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Keywords: | failure analysis fatigue analysis fatigue failure fatigue life variation fractography SEM |
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