Failure Investigation of Plastic Shredding Machine’s Flange Coupling Based on Mechanical Analysis

Ignatius Pulung Nurprasetio, Bentang Arief Budiman, Farid Triawan


This paper presented the investigation of failure mechanism of plastic shredding machine’s flange coupling which is made of cast steel. The machine unexpectedly stalled a few minutes after High-Density Polyethylene (HDPE) plastic bottles were fed into the machine. It was discovered afterward that the flange broke with the large crack surface. Finite element analysis (FEA) was performed to find the position and value of the critical stresses in the flange during operating condition. Subsequently, hardness test was conducted on the flange body to determine the Brinell hardness which was then converted into the approximate ultimate tensile strength (σu). As a result, a maximum Von Mises stress of 287 MPa was confirmed from the FEA to be concentrated in the flange’s keyway. Although this was found to be lower than the approximate σu obtained from hardness testing i.e. 449 MPa, the critical stress indicated an unstable condition which may induce a crack initiation any time when vibration or dynamic load occurs. Based on these analyses, it was concluded that the failure had been initiated by dynamic rather than static loading generated during machine stall condition. The dynamic load caused crack initiation at a stress concentration point of the keyway. The crack then propagated rapidly, breaking the flange body.


Failure analysis; Keyway; Fixed flange coupling; Finite element analysis; Hardness testing; Plastic shredding machine

Full Text:



Alsalem, S. M. (2009). Recycling and recovery routes of plastic solid waste (PSW): A review. Waste Management, 29(10), 2625-2643.

Berndt, F., van Bennekom A. (2001). Pump shaft failures - a compendium of case studies. Engineering Failure Analysis, 8, 135-144

Batdorf, S. B. (1975). Fracture statistics of brittle materials with intergranular cracks. Nuclear Engineering and Design, 35(3), 349–360.

Budiman, B. A., Suharto, D., Djodikusumo, I., Aziz, M., Juangsa, F. B. (2016). Fail-safe design and analysis for the guide vane of a hydro turbine. Advances in Mechanical Engineering, 8(7), 1–8.

Bugli, N. and Green, G. (2005). Performance and Benefits of Zero Maintenance Air Induction Systems. SAE Technical Paper, doi:10.4271/2005-01-1139.

Dahlberg, M. (1997). Micromechanical modelling of nodular cast iron, a composite material. International Journal of Cast Metals Research, 9(6), 319-330.

Gaško, M. and Rosenberg G. (2011). Correlation between hardness and tensile properties in ultra-high strength dual phase steels. Short communication Materials Engineering - Materiálové inžinierstvo, 18, 155-159.

Göksenli, A., Eryürek I. B. (2009). Failure analysis of an elevator drive shaft. Engineering Failure Analysis, 16, 1011–1019.

Han, H. S. (2014). Analysis of Fatigue Failure on the Keyway of the Reduction Gear Input Shaft Connecting a Diesel Engine Caused by Tortional Vibration. Engineering Failure Analysis, 44, 285-298.

Kurniawan, T., Fauzi, F. A. B., and Asmara, Y. P. (2016). High-temperature Oxidation of Fe-Cr Steels in Steam Condition – A Review. Indonesian Journal of Science & Technology, 1 (1), 107 – 114.

Li, W., Xia, F., and Luo, B. (2016). Failure Analysis of a High-Speed Shaft Crack. J Fail. Anal. and Preven. DOI 10.1007/s11668-016-0172-4.

Orthwein, W. C. (1979). A New Key and Keyway Design. Transactions of the ASME, 101, 338 – 341.

Pace, G., Pisharody, S., and Fisher, J. (2003). Plastic Waste Processing and Volume Reduction for Resource Recovery and Storage in Space. SAE Technical Paper 2003-01-2369, doi: 10.4271/2003-01-2369.

Pavlina, E.J. and Van Tyne, C.J. (2008). Correlation of Yield Strength and Tensile Strength with Hardness for Steels. Journal of Materials Engineering and Performance, 17, 888–893.

Pedersen, N. L. (2010). Stress concentrations in keyways and optimization of keyway design. The journal of strain analysis for engineering design, 45, 593-604.

Stephens, R. I. (2001). Metal Fatigue in Engineering (2nd ed.). John Wiley & Sons, Inc. ISBN 0-471-51059-9.

STN EN ISO 6506-1 (2014). Metallic materials. Brinell hardness test. Part 1: Test method.

Zambrano, O. A., Coronado, J.J., Rodrı´guez, S.A. (2014). Failure analysis of a bridge crane shaft. Case Studies in Engineering Failure Analysis, 2, 25–32.




  • There are currently no refbacks.

Copyright (c) 2017 Ignatius Pulung Nurprasetio, Bentang Arief Budiman, Farid Triawan

Creative Commons License
This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License.

Lisensi Creative Commons

Indonesian Journal of Science and Technology is published by UPI Press. This work is licensed under a Creative Commons Attribution-Sharealike 4.0.

StatCounter - Free Web Tracker and Counter View My Stats