Design Modification of Failure Mode Effect Analysis of Vibrating Feeder used in Crushing Industries
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This document presents a review of issues related to the fatigue of the support structure in vibrating feeders used in crushing industries, employing finite element analysis to address design modifications. It discusses various studies and suggestions to improve material handling through enhanced structural integrity and stress reduction. Key findings indicate that design changes, such as increasing plate thickness and optimizing stress distributions, can significantly extend the lifespan of vibrating feeder installations.
![IJSRD - International Journal for Scientific Research & Development| Vol. 2, Issue 09, 2014 | ISSN (online): 2321-0613
All rights reserved by www.ijsrd.com 131
Design Modification of Failure Mode Effect Analysis of Vibrating Feeder
used in Crushing Industries
Prashant Salat1
Amit Anakiya2
1
P.G. Student 2
Assistant Professor
1,2
Department of Mechanical Engineering
1
Gujarat Technological University, India 2
Veerayatan Group of Institutions, India
Abstract— Vibratin feeder technology is common in
material handling applications in numerous industries. This
review paper examines a problem with fatigue in the support
structure of a specific type of vibrating feeder. It also
reviews the theory behind vibrating feeder technology and
considerations that engineers who design them need to be
aware of. The finite element method is used to replicate a
fatigue problem in the support structure and various design
configurations are then analyzed to reduce the risk of the
conditions that caused the fatigue. The results are reviewed
and recommendations are made to improve the design and
modify the component dimensional parameters vibrating
feeder.
Key words: Vibrating feeder, Ansys, Goodman diagram,
FEMA
I. INTRODUCTION
The power, or motivating source, is attached to the feeder
screen at a prescribed angle. This angle will vary due to the
physical characteristics of the product. the entire feeder,
being either suspended or on isolation mounts, is moved
forward and upward, which also moves the material forward
and upward .the screen then returns back to its original
position. However, the material does not move backward
due to the slower action of gravity.
.
Fig 1: Box type vibrating feeder
In above fig vibrating feeder shown.in that fig also
shown that where the failure occurred in plate the joint
where Motor is mounted
The case study by Dr. Bhavesh P. Patel et al.
[1].and shown that the design of the vibratory screen used in
coal mining industry. The life of the vibrating screen is
more the six month but its fails half of design life because
loading bending stress is more the design available bending
stress so its fails, by changing supports in slot direction and
support height is change in such a way that the bending
stresses reduces within the limiting value.
Guo Sheng et al.[2] present paper they got that the
model established by finite element method using ansys
softwere. Vibrating screen box is fails due to the resonance
of working frequency and natural frequency so the stress
distributions and deformation in various parts of the screen
box under rated load like cracks of the bottom screen frame
and side panels, for improving the vibrating screening by
changing working frequency is beyond 10% of the natural
frequency for reducing resonance also modify structure
sieve box by connect flange to connect the bottom screen
frame with the side panels.
Su Ronghua ex al.[4] Using ANSYS, static analysis
and dynamic analysis were made for a certain large-scale
linear vibrating screen structure, weak links were found out
in structural design. The improved schemes were proposed
for vibrating screen structure. The static and dynamics
analysis’s results of each schemes were compared, the
optimal improved scheme was obtained. It is shown that, in
the vibrating screen structure, dynamic stress is oversize at
the positions of crossbeam, discharging beam and in-
material beam, the values are much larger than static stress,
and these are caused by notched specimen in beam
components .Optimal improved scheme of beam section is
finalized by computer simulation analysis, after substituting
it for original design, stress distribution of the vibrating
screen is ameliorated in working process, and the fatigue life
is increased.
Frantis’ek Novy et al.[5], in that ,a study of the
fatigue behavior of the bearing steel 100Cr6 and
austempered ductile iron tested between 103
and 1010
cycles.
Substance fatigue crack initiation related to microstructure
in VHC region (very high cycle). Subsurface fatigue crack
initiation is associated with internal structural
heterogeneities such as inclusions, micro pores, micro-
shrinkages, big graphite particles, long grain boundaries
suitably oriented to loading direction, small grains. and
found that fatigue crack in all 100cr6 bearing steel between
3.5×103
and 108
and also in ADI fatigue crack initiation
5×103
and 1010
.so observed that the s-n diagram depend on
type loading.
Gregory J et al.[6]. in that they shows that a study
of the apparent that the support structure of the existing
configuration was not adequate due to field failures stainless
steel fails below its yield strength. design changes in the
support structure components dimensional variables can
significantly lower stresses during operation. Simply
increasing the thickness of the support tube wall and
increasing the length of the bracket leg reduced stress in the
support tube where the cracking had occurred by a
substantial amount.
Dejan Momcˇilovic´a et al.[7] in this paper they got
that the analysis of load carrying capacity of the shaft and its
metallurgy failures of material and failure analysis done by
finite element method. they got that 20GSL material not
satisfied quality of shaft material. The shaft is fails due to
the corrosion of shaft found by finite element method.
S.K. Allah Karan et al.[8]. In that they show, the
Extensive fractographic and metallurgical analyses were
done by using a scanning electron microscope (SEM)
equipped with energy dispersive spectroscopy (EDS).
Analytical and mechanical testing results revealed that the
failure was due to the propagation of radial and vertical](https://image.slidesharecdn.com/ijsrdv2i9152-150923130422-lva1-app6891/85/Design-Modification-of-Failure-Mode-Effect-Analysis-of-Vibrating-Feeder-used-in-Crushing-Industries-1-320.jpg)
![Design Modification of Failure Mode Effect Analysis of Vibrating Feeder used in Crushing Industries
(IJSRD/Vol. 2/Issue 09/2014/029)
All rights reserved by www.ijsrd.com 132
cracks caused by fretting fatigue crack initiation at the
bolted joints where the side plate was connected to the sieve
housing. The crack initiate near bolted two different
materials.
J. P. Karthik et al.[9]. in this they are using
different approaches like marrow, Goodman, Gerber. they
found the when the loading sequences is predominately
tensile in a nature, the life of the more sensitive by
Goodman approaches is conservative but in loading is
predominantly tensile in nature, the life of the component in
morrow approach is more sensitive and is therefore
recommended. when using the time histories has zero mean
base, all three methods have been given approximately the
same results.
P. J. Tavner ex al.[10].in this paper they using
failure mode effect analysis method for wind turbine. The
RPN(risk priority number) data calculated from the FMEA
has been compared with field failure rate data for assemblies
of wind turbine.by FEMA ranked in assembly order giving a
clear picture of the unreliability of assemblies,
subassemblies and parts. This could be a useful tool for
designers to identify weak points in the wind turbine design.
Robert Stone et al.[11].he shown that The purpose
of this paper is to review the proper methods by which
spring manufacturers should estimate the fatigue life of a
helical compression springs during the design phase. The
paper will begin with a working definition of fatigue and a
brief discussion of fatigue characteristics. A short history
will be presented as to how fatigue test data has been
evaluated historically(e.g., S-N curves, Weibull-distribution,
modified Goodman diagrams,etc.) Spring-specific Modified
Goodman diagrams, presented in the new SMI Encyclopedia
of Spring Design, will be discussed. These Modified
Goodman diagrams have been sufficiently characterized to
facilitate direct calculation of predicted life. These
calculations will be presented along with a comparison to
the results of traditional graphical methods.
Mahmood Shafiee.[12].he shown Failure mode and
effects analysis (FMEA) has been extensively used by wind
turbine assembly manufacturers for analyzing, evaluating
and prioritizing potential known failure modes. However,
several limitations are associated with its practical
implementation in wind farms. The proposed FMEA
methodology provides an organized framework to combine
the qualitative (expert experience) and quantitative (SCADA
field data) knowledge for use in an FMEA study. The
building blocks of RPN method are discrete, and therefore
cannot represent effectively the strength of criticality. But,
the CPN method is based on the cost consequences of
failures which are expressed in monetary unit. So, it makes
the proposed FMEA methodology more understandable,
realistic and practical for wind farm managers
II. CONCLUSION
From review of above literature we can conclude the
following points:
Inclined deck Vibrating feeder is more screened
compare to liner deck screened.
Goodman, soderberg, Gerber, approaches are give
different values for total reversed cycle loading but
if zero base cycle it’s give similar values for each
approaches. .
FEMA method is the best method for finding
weakest part in the assemblies.
The fatigue crack initiation depends on micro-
structure material like metal or alloy, micro-pores,
micro-shrinkages, of alloy, micro-pores, micro-
shrinkages, long grain boundary.
The best design modifition in vibrating feeder box
plate by increasing thickness of plate, or by proper
welding done at plate where it fasted with the side
beam of the box of feeder.
REFERENCES
[1] Dr. Bhavesh P. Patel, Hiren R. Patel, “Design of
vibratory screen in used coal mining industry to
present failure- A case study” review of various
configurations and design techniques” in
International journal of research in modern
engineering and emerging technology, vol. 1,
Issue:1 february 2013.
[2] Guo Nianqin, Guo Sheng ,Luo Leping “Model
characteristics and finite element analysis of screen
box for ultra-heavy vibrating screen” in internation
conference and information and computing in 2010
.
[3] ZHAO Lala*, LIU Chusheng, YAN Junxia “a
virtual experiment showing single partical mation
on a linearly vibrating screen-deck in science direct
in 2010.
[4] Su Ronghua, Zhu Liuqing, Peng Chenyu “ CAE
applied to dynamic optimal design for large-scale
vibrating screen” in institute of electrical and
electronics engineering in 2010.
[5] Frantisek novy, marian cincala, peter kopas, otakar
bokuvka “Mechanisms of high-srength structural
materials fatigue failure in ultra-wide life region”
in material science and engineering in 2007.
[6] Gregory J Mcmillan jr “analysis of vibratory
equipment using the finite element method pp 33-
34 .
[7] Dejan momcilovic, zoran Odanovic, Radivoje
Mitrovic, Ivana Atanasovska “failure analysis of
hydraulic turbine shaft” in science direct in 2012.
[8] S.K. allah karam, M. Khodadad, M. Saadat Talab,
A.R. Moeim “ failure study in side plates of
vibrating sieve” in international journal of
mechanical and materials engineering ,vol.4,pp
118-122, 2009.
[9] J. P. Karthik, K. L. chaitanayan, C. Tara Sasanka
“fatigue life prediction of a parabolic spring under
non-consatant amplitude and proprosionl
loading”in international journal of advanced
science and technology,vol-46,2012.
[10]H.Arabian-Hoseynabadi, H.Oraee, P.J.Tanver
“failure modes and effects analysis (FEMA)for
wind turbine” in 22 June 2010.
[11]Robert stone “fatigue life estimates using Goodman
diagrams.
[12]Mahmood shafiee, fateme Diamohanmmadi “An
FEMA-Based risk assessment approach for wind
turbine system: A comparative study of onshore
and offshore in february 2014.](https://image.slidesharecdn.com/ijsrdv2i9152-150923130422-lva1-app6891/85/Design-Modification-of-Failure-Mode-Effect-Analysis-of-Vibrating-Feeder-used-in-Crushing-Industries-2-320.jpg)
Design Modification of Failure Mode Effect Analysis of Vibrating Feeder used in Crushing Industries
- 1. IJSRD - International Journal for Scientific Research & Development| Vol. 2, Issue 09, 2014 | ISSN (online): 2321-0613 All rights reserved by www.ijsrd.com 131 Design Modification of Failure Mode Effect Analysis of Vibrating Feeder used in Crushing Industries Prashant Salat1 Amit Anakiya2 1 P.G. Student 2 Assistant Professor 1,2 Department of Mechanical Engineering 1 Gujarat Technological University, India 2 Veerayatan Group of Institutions, India Abstract— Vibratin feeder technology is common in material handling applications in numerous industries. This review paper examines a problem with fatigue in the support structure of a specific type of vibrating feeder. It also reviews the theory behind vibrating feeder technology and considerations that engineers who design them need to be aware of. The finite element method is used to replicate a fatigue problem in the support structure and various design configurations are then analyzed to reduce the risk of the conditions that caused the fatigue. The results are reviewed and recommendations are made to improve the design and modify the component dimensional parameters vibrating feeder. Key words: Vibrating feeder, Ansys, Goodman diagram, FEMA I. INTRODUCTION The power, or motivating source, is attached to the feeder screen at a prescribed angle. This angle will vary due to the physical characteristics of the product. the entire feeder, being either suspended or on isolation mounts, is moved forward and upward, which also moves the material forward and upward .the screen then returns back to its original position. However, the material does not move backward due to the slower action of gravity. . Fig 1: Box type vibrating feeder In above fig vibrating feeder shown.in that fig also shown that where the failure occurred in plate the joint where Motor is mounted The case study by Dr. Bhavesh P. Patel et al. [1].and shown that the design of the vibratory screen used in coal mining industry. The life of the vibrating screen is more the six month but its fails half of design life because loading bending stress is more the design available bending stress so its fails, by changing supports in slot direction and support height is change in such a way that the bending stresses reduces within the limiting value. Guo Sheng et al.[2] present paper they got that the model established by finite element method using ansys softwere. Vibrating screen box is fails due to the resonance of working frequency and natural frequency so the stress distributions and deformation in various parts of the screen box under rated load like cracks of the bottom screen frame and side panels, for improving the vibrating screening by changing working frequency is beyond 10% of the natural frequency for reducing resonance also modify structure sieve box by connect flange to connect the bottom screen frame with the side panels. Su Ronghua ex al.[4] Using ANSYS, static analysis and dynamic analysis were made for a certain large-scale linear vibrating screen structure, weak links were found out in structural design. The improved schemes were proposed for vibrating screen structure. The static and dynamics analysis’s results of each schemes were compared, the optimal improved scheme was obtained. It is shown that, in the vibrating screen structure, dynamic stress is oversize at the positions of crossbeam, discharging beam and in- material beam, the values are much larger than static stress, and these are caused by notched specimen in beam components .Optimal improved scheme of beam section is finalized by computer simulation analysis, after substituting it for original design, stress distribution of the vibrating screen is ameliorated in working process, and the fatigue life is increased. Frantis’ek Novy et al.[5], in that ,a study of the fatigue behavior of the bearing steel 100Cr6 and austempered ductile iron tested between 103 and 1010 cycles. Substance fatigue crack initiation related to microstructure in VHC region (very high cycle). Subsurface fatigue crack initiation is associated with internal structural heterogeneities such as inclusions, micro pores, micro- shrinkages, big graphite particles, long grain boundaries suitably oriented to loading direction, small grains. and found that fatigue crack in all 100cr6 bearing steel between 3.5×103 and 108 and also in ADI fatigue crack initiation 5×103 and 1010 .so observed that the s-n diagram depend on type loading. Gregory J et al.[6]. in that they shows that a study of the apparent that the support structure of the existing configuration was not adequate due to field failures stainless steel fails below its yield strength. design changes in the support structure components dimensional variables can significantly lower stresses during operation. Simply increasing the thickness of the support tube wall and increasing the length of the bracket leg reduced stress in the support tube where the cracking had occurred by a substantial amount. Dejan Momcˇilovic´a et al.[7] in this paper they got that the analysis of load carrying capacity of the shaft and its metallurgy failures of material and failure analysis done by finite element method. they got that 20GSL material not satisfied quality of shaft material. The shaft is fails due to the corrosion of shaft found by finite element method. S.K. Allah Karan et al.[8]. In that they show, the Extensive fractographic and metallurgical analyses were done by using a scanning electron microscope (SEM) equipped with energy dispersive spectroscopy (EDS). Analytical and mechanical testing results revealed that the failure was due to the propagation of radial and vertical
- 2. Design Modification of Failure Mode Effect Analysis of Vibrating Feeder used in Crushing Industries (IJSRD/Vol. 2/Issue 09/2014/029) All rights reserved by www.ijsrd.com 132 cracks caused by fretting fatigue crack initiation at the bolted joints where the side plate was connected to the sieve housing. The crack initiate near bolted two different materials. J. P. Karthik et al.[9]. in this they are using different approaches like marrow, Goodman, Gerber. they found the when the loading sequences is predominately tensile in a nature, the life of the more sensitive by Goodman approaches is conservative but in loading is predominantly tensile in nature, the life of the component in morrow approach is more sensitive and is therefore recommended. when using the time histories has zero mean base, all three methods have been given approximately the same results. P. J. Tavner ex al.[10].in this paper they using failure mode effect analysis method for wind turbine. The RPN(risk priority number) data calculated from the FMEA has been compared with field failure rate data for assemblies of wind turbine.by FEMA ranked in assembly order giving a clear picture of the unreliability of assemblies, subassemblies and parts. This could be a useful tool for designers to identify weak points in the wind turbine design. Robert Stone et al.[11].he shown that The purpose of this paper is to review the proper methods by which spring manufacturers should estimate the fatigue life of a helical compression springs during the design phase. The paper will begin with a working definition of fatigue and a brief discussion of fatigue characteristics. A short history will be presented as to how fatigue test data has been evaluated historically(e.g., S-N curves, Weibull-distribution, modified Goodman diagrams,etc.) Spring-specific Modified Goodman diagrams, presented in the new SMI Encyclopedia of Spring Design, will be discussed. These Modified Goodman diagrams have been sufficiently characterized to facilitate direct calculation of predicted life. These calculations will be presented along with a comparison to the results of traditional graphical methods. Mahmood Shafiee.[12].he shown Failure mode and effects analysis (FMEA) has been extensively used by wind turbine assembly manufacturers for analyzing, evaluating and prioritizing potential known failure modes. However, several limitations are associated with its practical implementation in wind farms. The proposed FMEA methodology provides an organized framework to combine the qualitative (expert experience) and quantitative (SCADA field data) knowledge for use in an FMEA study. The building blocks of RPN method are discrete, and therefore cannot represent effectively the strength of criticality. But, the CPN method is based on the cost consequences of failures which are expressed in monetary unit. So, it makes the proposed FMEA methodology more understandable, realistic and practical for wind farm managers II. CONCLUSION From review of above literature we can conclude the following points: Inclined deck Vibrating feeder is more screened compare to liner deck screened. Goodman, soderberg, Gerber, approaches are give different values for total reversed cycle loading but if zero base cycle it’s give similar values for each approaches. . FEMA method is the best method for finding weakest part in the assemblies. The fatigue crack initiation depends on micro- structure material like metal or alloy, micro-pores, micro-shrinkages, of alloy, micro-pores, micro- shrinkages, long grain boundary. The best design modifition in vibrating feeder box plate by increasing thickness of plate, or by proper welding done at plate where it fasted with the side beam of the box of feeder. REFERENCES [1] Dr. Bhavesh P. Patel, Hiren R. Patel, “Design of vibratory screen in used coal mining industry to present failure- A case study” review of various configurations and design techniques” in International journal of research in modern engineering and emerging technology, vol. 1, Issue:1 february 2013. [2] Guo Nianqin, Guo Sheng ,Luo Leping “Model characteristics and finite element analysis of screen box for ultra-heavy vibrating screen” in internation conference and information and computing in 2010 . [3] ZHAO Lala*, LIU Chusheng, YAN Junxia “a virtual experiment showing single partical mation on a linearly vibrating screen-deck in science direct in 2010. [4] Su Ronghua, Zhu Liuqing, Peng Chenyu “ CAE applied to dynamic optimal design for large-scale vibrating screen” in institute of electrical and electronics engineering in 2010. [5] Frantisek novy, marian cincala, peter kopas, otakar bokuvka “Mechanisms of high-srength structural materials fatigue failure in ultra-wide life region” in material science and engineering in 2007. [6] Gregory J Mcmillan jr “analysis of vibratory equipment using the finite element method pp 33- 34 . [7] Dejan momcilovic, zoran Odanovic, Radivoje Mitrovic, Ivana Atanasovska “failure analysis of hydraulic turbine shaft” in science direct in 2012. [8] S.K. allah karam, M. Khodadad, M. Saadat Talab, A.R. Moeim “ failure study in side plates of vibrating sieve” in international journal of mechanical and materials engineering ,vol.4,pp 118-122, 2009. [9] J. P. Karthik, K. L. chaitanayan, C. Tara Sasanka “fatigue life prediction of a parabolic spring under non-consatant amplitude and proprosionl loading”in international journal of advanced science and technology,vol-46,2012. [10]H.Arabian-Hoseynabadi, H.Oraee, P.J.Tanver “failure modes and effects analysis (FEMA)for wind turbine” in 22 June 2010. [11]Robert stone “fatigue life estimates using Goodman diagrams. [12]Mahmood shafiee, fateme Diamohanmmadi “An FEMA-Based risk assessment approach for wind turbine system: A comparative study of onshore and offshore in february 2014.