Experimental and Finite Element Study of Bending Fatigue Failure: A Case Study on Main Shaft of a Gyrator Crusher
This study investigates the mechanism of a Gyratory crusher-located in Golgohar mining and industrial Co. specifically with a focus on stresses distribution and fatigue failure of its main shaft. At first step, the cross section of the fractured shaft is studied, and the crack growth is analyzed. Then, the rotational motion of the shaft and the oil temperature of oil circuit of equipment are monitored. Condition monitoring is used to help finding a better modification. Based on the results of this study, the main causes of shaft failure are identified, and corrective solution is offered to increase crusher performance, especially its main shaft life. To predict the efficiency of the proposed modification, finite element simulation is performed, and its results are compared with the similar modified cases. The comparison and interpretation of simulation results confirm the efficiency of proposed corrective method.
 D. Broek, Elementary Engineering Fracture Mechanics: Cluwer Academic Publishers, 1982.
 B. A. Wills and T. Napier-Munn, "6 - Crushers, Mineral Processing Technology" (Seventh Edition), ed Oxford: Butterworth-Heinemann, 2005, pp. 118-145.
 http://www.excelfoundry.com. (2013).
 R. A. Bearman and C. A. Briggs, "The active use of crushers to control product requirements" Minerals Engineering, vol. 11, pp. 849-859, 1998.
 M. Lindqvist and C. M. Evertsson, "Development of wear model for cone crushers" Wear, vol. 261, pp. 435-442, 2006.
 P. P. Rosario, R. A. Hall, and D. M. Maijer, "Liner wear and performance investigation of primary gyratory crushers" Minerals Engineering, vol. 17, pp. 1241-1254, 2004.
 P. P. Rosario, R. A. Hall, and D. M. Maijer, "Improved gyratory crushing operation by the assessment of liner wear and mantle profile redesign" Minerals Engineering, vol. 17, pp. 1083-1092, 2004.
 M. Lindqvist, "Energy considerations in compressive and impact crushing of rock" Minerals Engineering, vol. 21, pp. 631-641, 2008.
 "Gol-e-Gohar documentation, Gyratory crusher manual," ed, 2012.
 J. E. Shigley and R. G. Budynas, Mechanical Engineering Design, Eighth Edition: McGraw−Hill Primis, 2006.
 www.sandvik.com. (2013).