Port machinery forging is an important part of port machinery and equipment, which plays a key role in the safety and normal operation of ships. However, due to the bad working environment, high strength load and other factors, ship port mechanical forgings are prone to failure. This paper will analyze the possible failure modes and causes of mechanical forgings in ship ports, and put forward corresponding preventive measures to improve the safety and service life of ships.
Ship port machinery forgings are the key parts of port machinery equipment, mainly including drive shaft, gear, bearing and so on. These forgings play an important role in the equipment, such as transmitting power, supporting load and so on. Once these forgings fail, it will lead to the failure of the entire equipment, and may cause safety accidents in serious cases. Therefore, it is particularly important to analyze and prevent the failure of mechanical forgings in ship ports.
Failure analysis
The failure of mechanical forgings in ship ports is mainly manifested in two aspects: fracture and deformation.
Severance
Fracture is one of the most common failure forms of ship port mechanical forgings. Forgings may have internal defects in the manufacturing process, such as cracks, shrinkage holes, etc., which may expand to fracture during the operation of the equipment. In addition, the stress inflicted on the forgings during service exceeds their capacity, which can also lead to breakage. To detect whether there are internal defects in forgings, non-destructive testing (NDT) technology can be used in the manufacturing process, such as ultrasonic testing, X-ray testing, etc.
Amorphosis
The deformation is mainly due to the stress of the forging exceeding its elastic limit, resulting in plastic deformation. The deformation will affect the accuracy and stability of the equipment, and may cause equipment failure in serious cases. The yield strength and elastic modulus of forging material are important factors affecting its deformation. The detection of forging deformation can be achieved by measuring its geometric size, surface roughness and other parameters.
preventive measure
According to the results of failure analysis, the following preventive measures can be taken:
Manufacturing process control
In the forging process, the quality and process parameters of the forging should be strictly controlled. Adopt reasonable forging process and mold design to reduce forging defects. At the same time, strengthen the inspection of raw materials and post-forging heat treatment to eliminate or reduce internal defects and stresses.
Service process maintenance
During the use of the equipment, the forgings should be checked and maintained regularly. For key forgings, non-destructive testing technology should be regularly used to detect and deal with the existing defects in a timely manner. At the same time, strengthen the operation monitoring and maintenance of the equipment to ensure that the equipment operates under the specified working conditions to avoid the impact of bad working conditions such as overload and speeding on the forging.
Design optimization
In the equipment design stage, strength analysis and verification should be carried out to ensure that the forgings meet the strength and stability requirements required for equipment operation. At the same time, considering the mechanical properties of materials, working environment and other factors, select the appropriate materials and processes to improve the fatigue resistance and corrosion resistance of forgings.
The transmission shaft of a ship’s port machinery broke during operation. According to the failure analysis, it is found that there are unfused defects in the manufacturing process of the drive shaft. In order to prevent similar accidents from happening again, the following precautions have been taken:
Improvements to the manufacturing process, the use of higher quality smelting technology and more strict control of the manufacturing process to ensure the internal quality of materials.
Strict quality inspection of each batch of materials, using a variety of detection means, such as ultrasonic inspection, X-ray inspection, etc., to ensure the quality of the material is stable.
The design of the drive shaft is optimized to increase its strength and stability and avoid stress concentration.
Strengthen the maintenance and inspection of equipment, and regularly test and lubricate the drive shaft to ensure its normal operation.
After taking the above preventive measures, the service life of the ship’s port machinery transmission shaft has been significantly improved, and no similar fracture accidents have occurred again.
Ship port machinery forging is an important part of port machinery equipment, its failure has an important impact on the safety and normal operation of the ship. Based on the failure analysis of mechanical forgings in ship ports, this paper points out the possible failure modes and reasons, and puts forward the corresponding preventive measures. Practice shows that these preventive measures can effectively improve the quality and service life of ship port mechanical forgings. However, with the continuous development of technology and the continuous update of equipment, the failure problem of mechanical forgings in ship ports still needs continuous attention and research. In the future, more advanced manufacturing technologies and testing methods will be further explored to improve the performance and reliability of ship port mechanical forgings.
