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    Mechanical Reliability

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    Andre Mars
    The document discusses various modes of mechanical failure that can affect reliability. It lists common structural failures such as corrosion, fatigue, wear, and impact. It also discusses general mechanical failures caused by defects in design, materials, manufacturing, wear, installation, and deterioration over time. The document provides examples of sources of product failures in various industries. It concludes by outlining guidelines for designers to improve reliability, such as keeping designs simple, testing prototypes, incorporating redundancy, and considering human and maintenance factors.

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    Mechanical Reliability

    Uploaded by

    Andre Mars
    123 views3 pages
    The document discusses various modes of mechanical failure that can affect reliability. It lists common structural failures such as corrosion, fatigue, wear, and impact. It also discusses general mechanical failures caused by defects in design, materials, manufacturing, wear, installation, and deterioration over time. The document provides examples of sources of product failures in various industries. It concludes by outlining guidelines for designers to improve reliability, such as keeping designs simple, testing prototypes, incorporating redundancy, and considering human and maintenance factors.

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    Mechanical Reliability

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    The document discusses various modes of mechanical failure that can affect reliability. It lists common structural failures such as corrosion, fatigue, wear, and impact. It also discusses general mechanical failures caused by defects in design, materials, manufacturing, wear, installation, and deterioration over time. The document provides examples of sources of product failures in various industries. It concludes by outlining guidelines for designers to improve reliability, such as keeping designs simple, testing prototypes, incorporating redundancy, and considering human and maintenance factors.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    123 views3 pages

    Mechanical Reliability

    Uploaded by

    Andre Mars
    The document discusses various modes of mechanical failure that can affect reliability. It lists common structural failures such as corrosion, fatigue, wear, and impact. It also discusses general mechanical failures caused by defects in design, materials, manufacturing, wear, installation, and deterioration over time. The document provides examples of sources of product failures in various industries. It concludes by outlining guidelines for designers to improve reliability, such as keeping designs simple, testing prototypes, incorporating redundancy, and considering human and maintenance factors.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 3

    6 Mechanical reliability

    The well-reported failures, such as the Space Shuttle Challenger, the Three Mile
    Island and Chemobyl nuclear accidents, and the Bhopal gas escape, emphasize
    vividly the necessity for mechanical reliability.
    Buildings, bridges, transit systems, railways, automotive systems, robots, off-
    shore structures, oil pipe lines and tanks, steam turbine plates, roller bearings, etc.,
    all have their particular modes of failure affecting their reliability.
    While this book deals mainly with electronics, there are a number of common
    modes of mechanical failures, which are worth listing, e.g. with structures:

    (1) Corrosion failures


    (2) Fatigue failures
    (3) Wear failures
    (4) Fretting failures
    (5) Creep failures
    (6) Impact failures

    These may be considered the main failure modes, but there are of course many
    others, such as ductile rupture, thermal shock, galling, brineUing, spalling, radia-
    tion damage, etc., which are outside the scope of this book.

    General mechanical failures


    There are many causes of failure. Some have been listed by C. Lipson I as:
    (1) Defective design
    (2) Wrong application
    (3) Manufacturing defect
    (4) Wear-out
    (5) Incorrect installation
    ILipson, C. 'Analysis and Prevention of Mechanical Failures', Course Notes 8007, University of
    Michigan,Ann Arbor, June 1980.
    38 An Elementary Guide to Reliability
    (6) Failure of other parts
    (7) Gradual deterioration

    Some interesting sources of product failure in the following areas are given by
    Lipson 2 as:

    (1) Steel industry. Manufacturing and metallurgy (34%), design (58%) and ser-
    vice (8%).
    (2) Engines. Manufacturing (20%), engineering (40%), misuse in field (30%) and
    other causes (10%).
    (3) Truck industry. Manufacturing (12%), design (55%) and materials (33%).
    (4) Electrical industry. Manufacturing (37%), design (37%) and service (26%).

    Guidelines for designers in order to achieve higher reliability are given in B. S.


    DhiUon's book: Mechanical Reliability: Theory, Models and Applications)

    (1) Make design as simple as possible.

    2Lipson,C. Ibid.
    3B. S. DhiUon.Mechanical Reliability: Theory, Models and Applications. AIAA Education Series.
    370, L'EnfantPromenade,SW,Washington,DC 20024, UnitedStates of America.Published 1988.
    Mechanical reliability 39

    (2) Avoid introducing cost-saving procedures at the expense of reliability.


    (3) Make allowances for human error.
    (4) Make use of well-tried parts and materials.
    (5) Carefully test new designs.
    (6) Perform analyses of data received from the field.
    (7) Pay attention to data received from the field when making modifications and
    improvements.
    (8) In the case of critical parameters, consider using safety margins of three to
    six standard deviations.
    (9) Consider diagnosis of critical items.
    (10) Include facilities for inspection in the design.
    (11) Introduce redundancy whenever necessary.
    (12) Pay attention to the maintenance aspect with respect to reliability (Active
    Maintenance).
    (13) Take into account the effects of transport, handling and storage.
    (14) Make use of standard parts as much as possible.
    (15) Pay attention to the manufacturing aspects with respect to reliability.

    Some of these are touched upon in sections of this book, e.g. in Chapters 5, 6, 7
    and 8.
    Human reliability is often discussed and it is a fact that, apart from war, the
    highest toll of human life is caused by car accidents. These, in turn, are mainly
    caused by errors of judgement, making the main cause of failure - lack of human
    reliability.

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