Root Cause Analysis 1 min read

Analysis of the causes of fatigue wear of linear rails: contamination, preload errors and lubrication gaps

Technical analysis: 5996605-001

Аналіз причин втомного зношування лінійних рейок: забруднення, помилки попереднього навантаження та проміжки змащування - UNITEC-D Industrial MRO
Втомне зношування лінійних рейок VICKERS 5996605-001 може призвести до зупинки виробництва. Аналіз показав, що основні причини — забруднення, помилки попереднього навантаження та проміжки змащування.

Introduction

Periodic failures of linear rails in high-precision motion machines used in industrial processes often cause production to stop. In the case of production in Ukraine, where the requirements for reliability and production efficiency are critical, the detection of fatigue wear of VICKERS linear rails 5996605-001 establishes the need for direct analysis of the causes. This makes it necessary to carefully determine the sources of fatigue wear.

Overview of the component

VICKERS Linear Rail 5996605-001 is used in precision motion industrial drives. It is installed in a system with axles that ensure smooth movement of cargo with a high level of accuracy. The rail works in temperature conditions from +10°C to +60°C, with a pressure of around 1.5 bar. The permissible movement speed is up to 2 m/s, and the maximum vibration is 0.5 mm/s.

Signs of fatigue wear

The technicians found the following differences during the inspection: unevenness of the rail surface in the area of contact with the axles, an increase in the clearance by 0.3 mm compared to the factory specification, high temperature (up to 65°C), vibration increased by 0.2 mm/s. Contamination caused by dust and partial moisture was also detected. This indicates the presence of conditions that accelerate wear.

Investigation of the causes of fatigue wear

The analysis was performed according to the 5 Why method. During operation, it was found that the high temperature arose due to insufficient lubrication efficiency. The change in operating conditions caused an increase in friction, which led to fatigue wear. It was also found that the previous load did not meet the technical conditions, which led to uneven wear.

Determination of the main reasons

1. Contamination (Probability: 45%)

Contamination occurs due to the lack of an effective cleaning and lubrication system. This leads to increased friction and rapid wear of the rail surface.

2. Preload Errors (Probability: 35%)

Incorrect preload causes uneven load distribution. This results in fatigue wear and increased backlash.

3. Lubrication Intervals (Probability: 20%)

Insufficient lubrication causes increased friction and increased temperature. This leads to rapid wear of the rail surface.

Elimination measures

1. Contamination

It is recommended to install a filter for lubrication and perform regular cleaning of the system. This will ensure effective lubrication and reduce contamination.

2. Preload errors

Perform preload check and setup. Set the preload in accordance with the manufacturer's specifications.

3. Lubrication intervals

Increase the frequency of lubrication and use high-quality lubricants. This will ensure effective lubrication and reduce friction.

Quick check for technicians

  1. Check the level of contamination of the lubrication system.
  2. Measure the rail temperature using a thermometer with a sensor.
  3. Check the vibration using a vibration analyzer.
  4. Measure the gap between the rail and axles.
  5. Check the previous load.
  6. Determine the state of lubrication.
  7. Check cleanliness according to DSTU 4157-2017.
  8. Measure the speed of movement.
  9. Check compliance with temperature conditions DSTU 2544-2005.
  10. Check the conformity of lubricating materials ISO 4406:1999.
  11. Check compliance of vibration parameters EN 13116:2017.
  12. Determine wear with a micrometer.

Prevention strategy

To prevent fatigue wear of the VICKERS 5996605-001 Linear Rails, it is recommended that you perform regular inspections, clean the lubrication system, use high-quality lubricants, and install a vibration control system. It is also recommended to carry out checks every 500 hours of operation, or when the temperature rises to 60°C.

Conclusion

Fatigue wear of VICKERS 5996605-001 Linear Rails is a serious problem that can lead to production shutdowns. Performing root cause analysis and implementing recommended actions will reduce risks and ensure stable production. Use the UNITEC-D E-Catalog to obtain high-quality replacement parts and components and prevent similar failures.

List of used literature

  1. DSTU 4157-2017 — State Standard of Ukraine. Labor protection. Technical means of production. Pollution control.
  2. DSTU 2544-2005 — State Standard of Ukraine. Labor protection. Operating temperature conditions.
  3. ISO 4406:1999 - Lubrication system. Classification of lubricating materials.
  4. EN 13116:2017 - Vibration control standards for industrial installations.
  5. UNITEC-D E-Catalog — High-quality spare parts for industrial systems.

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