Module 3 – Chain Failure Modes
Transmission chain
Key Chain Failure Types
§ Overload- chain subjected to excessive one-
off load which causes permanent deformation
of material and leads to very short chain life.
§ Fatigue- chain subjected to repetitive high
load beyond the endurance limit, causing it to
eventually fracture.
§ Wear- Load normally between pin and bush
eventually wears away material such that the
chain stretches beyond its usable limit. Most
chain are designed to fail due to wear.
Overload Mechanism
Load vs Extension
§ In normal operation chain returns
load
to its original length when a load is
applied and released.
§ At very high loads (Above 65% of
breaking load) material does not
return to its former condition- it
chain length has goes ‘plastic’
changed
§ Each load ‘stretches’ the chain
until it breaks.
extension
How to Identify Overload
Look for evidence of deformed material.
The chain plate in the top image has
failed in overload
§ Stretching of the side plates can be
seen
Overload failure can also cause the pin
to break
§ Outer plates then bend outward
§ The chain literally unzips
Fatigue - Mechanism
S-N Curve
§ Applying a repeated load to a
chain will eventually cause it to fail.
The lower the load, the higher the
Load
life.
§ Results can be plotted on a curve.
§ At loads before the bottom of the
Load for infinite life curve, the life is infinite. The failure
mode then becomes wear.
Cycles
How to Identify Fatigue
§ Components fail without deformation
§ Look for hairline cracks (can be very
small)
The picture shows a fatigue failure in an
advanced state
§ Origin can be seen when the plate is
Point of origin removed.
§ Classic “beach rings” show progressive
failure.
Wear - Mechanism
Wear Curve § Running a chain results in the chain
extending in length.
Elongation
§ This is due to the pin wearing against the
bush when it engages with the sprocket.
§ Initial wear is high, it then settles down
Bedding In to a very low level.
Steady state § Correctly selected chain will result in
15,000 hours life for a 2% chain extension.
§ The first few hours of running are shown
Time on the curve.
Why does Wear Happen ?
§ Bush and pin surfaces may look smooth
but:
Rubbing speed
§ At microscopic level they are jagged
§ The jagged parts rub against each
other and produce debris
Lubricant § The amount of wear depends on:
- Load
- Speed of rubbing
- Lubricant
- Environment
Load
How to Identify Wear
§ Wear takes place between the
pin and the bush.
§ Generally the pin wears more.
§ Most chain will run
satisfactorily up to 2%
elongation
§ Measure the distance between
say 10 chain pins and compare
with the original catalogue
pitch.
Other Chain Failure Modes
There are many other less common
ways in which a chain can fail. Some
example follow.
Galling
§ Lack of lubrication or
excessively high running
loads
§ Metal to metal welding
§ Smeared and grooved
surface
§ This pin is also corroded.
Corrosive Environment
§ In very harsh conditions a
combination of water and
corrosive chemicals can
caused havoc.
§ This is an extreme example
Abrasive Conditions
§ This sprocket has run
with poor lubrication in a
dusty environment.
Summary
§ Chain can fail mechanically in the following ways:
- Overload- should never happen
- Fatigue- should try to design around this
- Wear- the normal mode
§The bush/pin is the critical area
§Normal wear life is 15 000 hours
§Other modes of failure are possible but less
frequent
Module 3 – Chain Failure Modes
Transmission chain
