Analysis of the Fracture and the Repair of the Screw Spindle of a Friction Screw Press
Abstract
1. Introduction
2. Examination of the Cause of the Screw Spindle Fracture in the Drive Mechanism
- Visual examination;
- Experimental test procedure.
2.1. Visual Examination
2.2. Experimental Test Procedure
- Testing of the chemical composition and mechanical properties of the materials [21];
- Metallographic examination of the fracture surfaces.
2.2.1. Test of the Chemical Composition and Mechanical Properties of the Materials
2.2.2. Metallographic Examination of the Fracture Surfaces
- Magnified material microstructure in the grinding, polished and etching state with fractures in the plastic fracture zone (Figure 6).
2.2.3. Discussion of the Examination Results
3. Finite Element Analysis of the Stress State of the Screw Spindle
3.1. ANSYS FEM Analysis
3.2. Discussion of the FEM Analysis Results
- The stress concentration is highest in the connection zone between the bottom end of the screw spindle and the presser (at the point of the conical pin).
- The stress state level in the screw spindle fraction zone is very high.
- The maximum value of uniaxial stress is located in the fracture zone at the point of the conical pin (see (Figure 10)). The value of σe,max = 555.08 N/mm2 was read. This value was obtained at the maximum forging force (Fmax = 1600 kN).
- The safety factor (Equation (3)) of the screw spindle at the critical point of the edge of the opening is greater than the minimum required SFmin = 1.00. However, the safety factor has a low value. It is recommended that for ductile materials, the degree of safety should have the lowest value SF = 1.30. Also, it is recommended that the safety factor should be within the limits for strict classic design SF = 1.30…1.50 [38].
4. Screw Spindle Repair
- Elaboration of technical drawings;
- Repair welding;
- Checking the safety of the welded joint;
- Techno-economic analysis of the repair.
4.1. Elaboration of Technical Drawings
4.2. Repair Welding
- Machining of the main (healthy) part of the screw spindle (I): transverse machining by turning at the fracture point to a length of 1246.5 mm as well as boring and internal turning of a hole ø50 × 50 mm.
- Machining of the screw spindle extension (II): transverse machining by turning to a diameter of ø120, longitudinal machining by turning a cylindrical surface ø120 × 158.5 mm, machining by turning a cylindrical surface ø50 × 50 mm and transverse machining by turning to a diameter of ø120 and a length of 158.5 mm.
- Thermal treatment of the screw spindle extension (2) [12].
- V-grooving (see Figure 12). The welding surfaces (cones of the groove) on the healthy part of the screw spindle (I) and its extension (II) are formed by a mechanical process. Machining of the cone of the groove was performed by turning and grinding.
- Bonding the healthy part of the screw spindle (I) with the extension of the screw spindle (II), so that the fit has a small lap (ø50H7/n7).
- Control of the performed repair.
4.3. Checking the Safety of the Welded Joint
4.3.1. Analysis of Starting Data
4.3.2. Solution
4.4. Techno-Economic Analysis of Justification of the Repair
5. Conclusions
- Visual examination of the screw spindle indicated that the initial fracture occurred in the immediate vicinity of the pin opening. The expansion of the crack, during further exploitation, led to the final failure by cracking at the point of the conical pin (Figure 4a).
- Test data on the chemical composition and mechanical properties of the material (50CrMo4 steel) of the samples taken from the fracture point of the screw spindle of the drive mechanism show that they are not within the prescribed limits. This means that the most likely cause of the screw spindle fracture is defects in the material. The loss of quality of the steel, from which the threaded spindle was made, during long exploitation, most likely occurred due to stroke load.
- A metallographic examination of the fracture surfaces of the screw spindle showed that the fracture did not occur due to non-metallic inclusions in the material.
- Finite element analysis showed that the point at the screw spindle with the calculated maximum stress corresponds to the location of the fatigue crack.
- Additional causes of the screw spindle fracture can be as follows: dynamic stroke load and a low value of the safety factor.
- The procedure for the realized repair of the damaged screw spindle is presented.
- It was shown that there is a techno-economic justification for the realized repair of the screw spindle. In other words, it was shown that the applied repair welding of the screw spindle has a significant advantage compared to replacing it with a new one.
- The friction screw press continued to perform its function successfully until the writing of this paper.
- This paper leaves space for further research on the problem of breakage of screw spindles on different machines (e.g., friction screw presses, mechanical column lifts, …).
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
Abbreviations
FSP | Friction screw press |
FEM | Finite element method |
CAD | Computer-Aided Design |
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Elements | C | Si | Mn | P | S | Cr | Mo | Ni | ||
---|---|---|---|---|---|---|---|---|---|---|
To: 50CrMo4 | Recommended values [31] | From | 0.46 | - | 0.50 | - | - | 0.90 | 0.15 | - |
To | 0.54 | ≤0.40 | 0.80 | ≤0.035 | ≤0.035 | 1.20 | 0.30 | - | ||
Test values | 0.363 | 0.272 | 0.460 | 0.0172 | 0.0143 | 1.603 | 0.249 | 1.457 |
Mechanical Properties | Tested HV (N/mm2) | 0.2 Proof Stress Rp0.2 (N/mm2) | Tensile Strength Rm (N/mm2) | Elongation at Fracture A5 (%) | Notch Impact Energy K (J) | ||
---|---|---|---|---|---|---|---|
To: 50CrMo4 100 < ∅d ≤ 160 | Recommended values [31] | From | - | - | 850 | - | - |
To | - | ≥650 | 1000 | ≥13 | ≤30 | ||
Values of tension properties calculated via tested HV [29] | 1 | 230 | 599.54 | 796.36 | - | - | |
2 | 229 | 596.66 | 792.63 | - | |||
3 | 230 | 599.54 | 796.36 | - | - |
Type of Inclusion | |||||||||
---|---|---|---|---|---|---|---|---|---|
Field of View | A | B | C | D | DC | ||||
Fine | Thick | Fine | Thick | Fine | Thick | Fine | Thick | ||
1 | 0.5 | - | - | - | - | - | 0.5 | - | - |
2 | 0.5 | 0.5 | - | - | - | - | 0.5 | - | - |
3 | - | 0.5 | 0.5 | - | 0.5 | - | 0.5 | - | - |
Final estimation | 0.5 | 0.5 | 0.5 | - | 0.5 | - | 0.5 | - | - |
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Vasiljević, R.; Pantelić, D. Analysis of the Fracture and the Repair of the Screw Spindle of a Friction Screw Press. Machines 2025, 13, 309. https://doi.org/10.3390/machines13040309
Vasiljević R, Pantelić D. Analysis of the Fracture and the Repair of the Screw Spindle of a Friction Screw Press. Machines. 2025; 13(4):309. https://doi.org/10.3390/machines13040309
Chicago/Turabian StyleVasiljević, Rade, and Dragan Pantelić. 2025. "Analysis of the Fracture and the Repair of the Screw Spindle of a Friction Screw Press" Machines 13, no. 4: 309. https://doi.org/10.3390/machines13040309
APA StyleVasiljević, R., & Pantelić, D. (2025). Analysis of the Fracture and the Repair of the Screw Spindle of a Friction Screw Press. Machines, 13(4), 309. https://doi.org/10.3390/machines13040309