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<p>This study investigates the fatigue failure of a conveyor roller shaft through macroscopic and microscopic fracture surface examination, metallographic characterization and finite element analysis (FEA). The findings indicate that failure occurred by rotating bending fatigue under high nominal stresses, as evidenced by multiple crack origins at the shaft periphery and root fillet region. The shaft material, S335JR in annealed condition, was inadequate for the imposed dynamic stresses. Finite element analysis revealed that the 0.5&#xa0;mm fillet radius at the shaft transition increased nominal stresses from ~ 200 to 359&#xa0;MPa, amplifying fatigue damage. Redesign of the fillet radius from 0.5 to 1.5&#xa0;mm reduced maximum stress by ~ 20%, increasing predicted fatigue life by nearly threefold. Preventive measures, including optimized geometry and selection higher fatigue strength materials like quenched and tempered steel instead of structural steel, are recommended to mitigate future failures.</p>

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Fatigue Failure of a Conveyor Roller Shaft and Design Improvement

  • 期刊论文

  • 发表日期：

    2026年1月8日

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  • Oguzhan Kurt,
  • Huseyin Tursun,
  • Aptullah Karakas,
  • Bulent Acar

摘要

This study investigates the fatigue failure of a conveyor roller shaft through macroscopic and microscopic fracture surface examination, metallographic characterization and finite element analysis (FEA). The findings indicate that failure occurred by rotating bending fatigue under high nominal stresses, as evidenced by multiple crack origins at the shaft periphery and root fillet region. The shaft material, S335JR in annealed condition, was inadequate for the imposed dynamic stresses. Finite element analysis revealed that the 0.5 mm fillet radius at the shaft transition increased nominal stresses from ~ 200 to 359 MPa, amplifying fatigue damage. Redesign of the fillet radius from 0.5 to 1.5 mm reduced maximum stress by ~ 20%, increasing predicted fatigue life by nearly threefold. Preventive measures, including optimized geometry and selection higher fatigue strength materials like quenched and tempered steel instead of structural steel, are recommended to mitigate future failures.