Failure Analysis - Forensic Engineering
ANALYSIS OF A FRACTURED RETENTION STUD FROM A CNC TOOL HOLDER COLLET
A fractured retention stud from a CNC auto change tool holding collet and a comparison retention stud from the same manufacturer were analyzed to determine the cause of failure.  One of the retention studs was fractured through the shank in a spiral fashion from the region of the first thread.  A second stud was intact but cracked in the same manner.  Failure analysis of fractured tool steel
Failure analysis of a brittle torsional overload fracture surface
A close-up view of the fractured retention stud.  A brittle torsional spiral fracture is observed. 
A detailed SEM image of the brittle intergranular fracture found along the outer surface in the area of initiation.  Scanning Electron Microscope (SEM) image of a brittle intergranular fracture
Failure analysis of brittle cracking of thread root
View of cracking in the root of the first thread in a cross-section through the cracked stud.  The wide opening of the crack indicates a high stress load and the likely initiation site.  A high magnification view of the crack tip is detailed in the following image.
The crack appears to follow prior austenitic grain boundaries indicating brittle fracture. 
Metallographic microstructure evaluation of intergranular brittle cracking

CONCLUSIONS: 

Results indicate that the retention stud fractured due to instantaneous torsional overload.  The case-hardened steel is in a brittle condition and does not give, but cracks when overtorqued.  A torque wrench adaptable to the stud was devised so that the proper torque loading could be maintained.  No further failures have been observed.

Forensic examination of a failed component can prevent recurring failures, help with preventive detection, and suggest remedies. If you have a component failure that you would like investigated, just take a moment to fill in our information request form and we'll gladly give you an estimate. 

Metallurgical Technologies, Inc., P.A.
160 Bevan Drive, Mooresville, NC 28115


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