Authors: Bošnjak, Srđan
Petković, Zoran
Atanasovska, Ivana 
Milojević, Goran
Mihajlović, Vaso
Title: Bucket chain excavator: Failure analysis and redesign of the counterweight boom supporting truss columns
Journal: Engineering Failure Analysis
Volume: 32
First page: 322
Last page: 333
Issue Date: 1-Sep-2013
Rank: M21
ISSN: 1350-6307
DOI: 10.1016/j.engfailanal.2013.04.012
The supporting truss of the counterweight boom is a vital part of the bucket chain excavator's (BCE) superstructure. The occurrence and propagation of cracks in the supporting truss columns' heads may lead to BCE collapse. The goals of the study presented in this paper were to: (a) diagnose the cause of cracks occurrence; (b) define the reconstruction design of the supporting truss columns and (c) validate the reconstructed structure by numerical-experimental analysis. In order to clarify the causes of cracks occurrence, experimental investigations were performed with the purpose of defining the chemical composition, tensile properties, impact toughness and macrohardness of the columns' material. Metallographic examinations were also conducted. Based on the results of finite elements analyses (FEA) and experimental analyses it can be concluded that cracks are caused by the 'design-in' defects. The redesign solution enabled repair and reconstruction in field conditions, without previously dismantling any substructure of the BCE superstructure. Thereby the time required for performing reconstruction is shortened and indirect costs due to the BCE downtime are considerably diminished. Both the experimental analysis of the stress state of the reconstructed columns in regular working conditions and the failure-free exploitation have confirmed the validity of the reconstruction design, while the BCE excavated approximately 8.5×106t of coal and 1.8×106m3 of overburden after the reconstruction.
Keywords: Bucket chain excavator superstructure | Experimental validation | Failure diagnostics | Finite element analysis | Redesign
Publisher: Elsevier
Project: Sustainability and improvement of mechanical systems in energetic, material handling and conveying by using forensic engineering, environmental and robust design 

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