Factors That Can Contribute to Failure of Mechanical Equipment

Mechanical equipment can be susceptible to failure, particularly when it is operated in unfavorable conditions. There are a number of factors that can contribute to this, including overworking, fatigue, corrosion, and adhesive wear. Fortunately, there are measures you can take to minimize these risks, and the following article explains how. Get to the bottom of the cause of your fire or explosion with our expert Mechanical equipment failure analysis.

Adhesive wear

• Adhesive wear is one of the most common types of wear on mechanical equipment. It causes the metal to pull off or the surface to fracture. It is important to prevent it from occurring. There are several techniques that can be used to reduce the chances of this type of wear.
• The first step is to understand how adhesive wear develops. It is a process that is similar to friction. However, there are some differences. For instance, adhesive wear can occur even in lubricating systems. Its severity can also be affected by the type of lubricant and the amount of wear.
• Adhesive wear is a very serious problem. Excessive wear can cause damage to the equipment, leading to premature failure. In fact, adhesive wear can account for up to 70% of typical component failures.

Corrosion

• Corrosion is a common cause of damage to equipment in industrial environments. This is because metals interact with chemicals and moisture in the air, which accelerates their degradation. This makes it important for manufacturers to select the right materials for their applications.
• For example, rust forms when iron is exposed to water. This can cause damage to hard disks and computer systems. It can also destroy communication facilities.
• Another reason for corrosion is continuous high temperatures. This can encourage more oxidation in oil. To prevent this, select materials with a low electric potential difference.
• Increasing pollution levels are also a contributor. Sulfur dioxide is especially aggressive towards copper contacts in electronic equipment.

Fatigue

• Fatigue is one of the common causes of failures in mechanical equipment. It is an irreversible condition that can cause irreparable damage. Therefore, preventing it is essential. The best way to do this is to develop a maintenance schedule for your machinery.
• Among other things, regular maintenance can help prolong the life of your equipment. The cyclic stress created during operation can contribute to fatigue. Keeping your equipment in good condition can also reduce the chances of problems occurring.
• Some of the major types of fatigue include vibration and bending. Vibration fatigue occurs due to vibration damages in equipment, while bending fatigue is due to a continuous bending stress.

Erratic failures

• Erratic failures in mechanical equipment are a frustrating problem that can be difficult to diagnose. They are usually caused by sudden overloads in hydraulic or electrical systems.
• Keeping machinery running at full capacity is an important step in production. But, if an unexpected breakdown occurs, downtime is inevitable. This can affect productivity, costing companies money, and disrupting production.
• Some common causes of equipment failure include operator error, improper maintenance, and wear and tear. But, most failures can be avoided with routine maintenance and preventative care.
• Having a thorough knowledge of the machinery is the key to predicting failures. Once you have an understanding of the mechanisms, you can develop a preventative maintenance plan that fits your company's needs.

Overworking

• A malfunctioning mechanical piece of equipment can cause a number of problems for a business. This can lead to lost time, productivity, and money. The best way to prevent this is to understand the common causes of failure and what you can do about it.
• One of the most common causes of equipment failure is overuse. You can reduce your risk by using preventive maintenance programs. These include checking the machine's operation status and updating the parts to keep it in top shape.
• Unexpected breakdowns can also happen, so it's important to schedule regular maintenance checks. This will help reduce downtime and eliminate unnecessary stress on the machine.

Untrained operators

• If you operate heavy equipment, you should be familiar with the common causes of equipment failure. Investing in adequate operator training can help you keep the equipment operating in tip-top condition, reducing the risk of injury and breakdown.
• When you start your machine, be sure to check for warning lights and other signs that the equipment is not functioning properly. This way, you can stop the issue before it worsens.
• Most companies have a standard operator training program. This program trains operators on the proper use and care of their equipment. It also includes best practices for using and troubleshooting machinery.
• Some untrained operators push their machines too hard or operate them in a way that isn't safe. This can cause a variety of accidents, including serious injury or even death.