International Journal of Emerging Technology and Advanced Engineering

Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 9, September 2014)

Study of Fork Tube Failure in Motorcycle Using Scanning

Electron Microscope
Sudhir Pawaskar1, Prabhakar M. Bhovi2
1,2

Assistant Professor, Department of Mechanical Engineering B.V. Bhooomraddi College of Engineering and TechnologyHubli, Karnataka
Components of a system can fail one of many ways, for
example excessive deformation, wear, rupture, corrosion,
burning-out, degradation of specific properties. The
credibility of failure analysis lies in their ability to identify
corrective actions by determining the causes of the failure.
Hence the following study is an effort to understand the
root cause of the failure in the fork tube of motorbike by
carrying out various metallurgical observations in the form
of SEM and EDS analysis.

Abstract Fork tubes, in motorcycles forms the front

suspension assembly allowing the front tyre to maintain
contact with the road for better handling and braking.
Motorbike forks are generally made from cold drawn
seamless tube of alloy steel ( as per BIS specification) with a
coating of hard chrome. Fork tube failure of motorcycle is one
which would cause injury and even death. The study of
fractured surface founds to be an important aspect in order to
study
the
component
chemical
composition
and
microstructure of the fork tube of the motorcycle to minimize
the effect for impact load.
The present work has been carried out by the
characterization of the fractured surface through
micrographs and fractographs, of the fractured/pre-fractured
surface of the fork tube using Scanning Electron
Microscopy(SEM) and Energy dispersive spectroscopy (EDS).
It is observed that there was a substantial variation in the
primary composition of the fork tube with increased Carbon
% (Mass %) which surprisingly measures to 29% at the
fractured area when compared to 3.23 % at pre-fractured
area. Resulting to this the specimen had undergone brittle
fracture.
Keywords
Microstructure.

Fork

Tube,

SEM,

II. EXPERIMENTAL PROCEDURE

When failed components are received in the laboratory it
is customary to document their condition. The failed fork
tube was received from client, which was of 202 mm
length, 26 mm diameter and thickness of 4 mm with
fractured surface at one end. (As shown in figure 2.1 and
2.2.1). The specimen was kept in open atmosphere in a
polyethene bag. The Specimen of the fractured fork tube is
as shown in Fig 2.1

Fractography,

I. INTRODUCTION
The current study is a fractured analysis, carried out on
the fractured fork tube. Fork tube is an integral part of a
motorcycles front (telescopic) suspension system. It
connects the front wheel and axle to its frame. Fork tube
compresses and extends to adjust for inconsistencies on the
road allowing the front tyre to maintain contact with the
road for better handling and braking. The specimen was
obtained from a local client. The motorbike was subjected
to impact loading (in form of accident) cause of which the
specimen underwent premature fracture. Hence the
metallurgical analysis was needed to understand the cause
of failure.

Figure 2.1 showing failed fork tube collected client

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International Journal of Emerging Technology and Advanced Engineering

Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 9, September 2014)
2.1 Preparation For Post Facture Sample

Initial polishing was carried out using 400 grid pad until
the lines were completely in one direction on the
observation face of the sample. Then with less pressure
compared to before using 600 grid pad the sample was
polished perpendicular to the lines observed from previous
polish till the lines disappears. Similarly polishing is
carried out with other grid pads till the mirror finish is
obtained at the observation surface. Further the sample was
polished using disc polishing machine by applying
diamond paste and holding it against velvet cloth to obtain
the good scratch free finish. The etchant NITAL 5% was
used to etch the polished face in order to see grains
structure using microscope. Then the sample was well
preserved by covering with cotton and placed in dessicator
which was initially cleaned using acetone to minimise
environmental effect on it.

Figure 2.1.1 of post fractured sample after finishing operation

The fractured fork tube was cut to a length of 10 mm

using high precision blade cutter with oil-water emulsions
as coolant so that no phase transformation is observed due
to the heating by the cutting operation carried out on the
specimen surface. Then the sample was carefully brushed
with the cotton using acetone to clean the dirt particles
from the fractured surface. The sample was well preserved
by covering with cotton and placed in desiccators.
Precautions were taken to avoid any possible
environmental influence that could affect the specimen.

III. EXPERIMENTAL PROCEDURE

3.1 Obsrevations
The Fractured Surface for the given specimen is as
shown in the figures 3.1, 3.2 and 3.3. It clearly indicates the
characteristic of bending and sheared surface caused by
high sudden impact stress.

2.2 Preparation For Pre Facture Sample

The same fractured fork tube at a distance of 75mm from
fractured was cut to a length of 8 mm using high precision
blade cutter with oil-water emulsions as coolant so that no
metallurgical phase change occurs during the process.

Figure 3.1

The area of final fracture is large, of total area,

indicating that the material had undergone severe
deformation by twist/Bending. The beachmarks (Figure
3.3) and striations observed indicates the nature and
characteristics, fracture that had propagated from from the
initiation site, and the location of final fracture(fig 3.1).

Figure 2.2.1 pre fractured sample after finishing operation

The specimen, were then prepared for necessary

metallurgical observations through SEM. The specimen
were carefully polished using relevant polishing papers of
grid sizes of 400, 600, 800, and 1000 to study the
microstructure of the sample.
Figure 3.2

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International Journal of Emerging Technology and Advanced Engineering

Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 9, September 2014)

Figure 3.2.1.1

This can be seen in Fig 3.2.1.2 and 3.2.1.3. This result

can be accommodated to the presence of large quantities of
cementite at the Grain baundry region and pearlite at the
grain.

Figure 3.3

Initiation of fracture occurred around the circumference

of the fork tube. The bending of a fork tube near the
fracture surface till the depth of 14mm from the fractured
end clearly indicate the load was nearly perpendicular to
axis of the fork tube (Figure 3.1).
Clearly the shearing lines at initial point of contact with
the fork tube are visible (Figure 3.3). The bulging at the
surface of facture shows that the circular cross-section was
changed to elliptic due to sudden impact load before the
specimen was fractured (Figure 3.2). Due to bulging the
thickness of the fork tube has changed from 4mm to 2mm
at fractured surface (Figure3.2).

Figure 3.2.1.1

The grain size distribution can be seen as uneven

relating to heterogeneous microstructures (Figure 3.2.1-2).

3.2. SEM Analysis

3.2.1. Pre Fracture Surface
The microstructure analysis was carried out for the
samples involving both pre fractured and post fractured
surface of the fork tube using Scanning Electron
Microscope (JSM-6380LA, JEOL, JAPAN). The Figure
3.2.1-1 shows the pre fractured sample which has been
observed using SEM. The fork tube end was prepared for
metallurgical studies, after appropriate polishing
procedures.

Figure 3.2.1.1

The same can be observed from figure (3.2.1.4)

3.2.2. Pre Fracture Surface
Subsequently the given fractured specimen were
observed under SEM, to understand the nature of fracture,
as shown below. The images shows dimples at the
fractured locations, which could possibly be due to the
intergranular fracture (Figure 3.2.2-2). Figure 3.2.2-4
shows microstructure of intergranular fracture on the
elliptical edge. This might be possibliy because of high C,
which hence form Carbides at the grain baundries being
present at the fractured location and can be validated
through the EDS analysis shown in fig(3.3.2.2)

Figure 3.2.1.1

The microstructural examination carried out on the

specimen at 1000X,4000X and 10,000X reveals fine grain
structure of the material with some precipitates observed as
being distributed evenly throughout the grain-boundries.

Figure 3.2.2.1

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3.3. Elemental Analysis
The element analysis was carried out at SEM using
Energy Dispersive Spectrometer for both the samples inorder to understand the composition and amount of various
allowing elements for both pre-fractured and fractured
specimen. The results obtained shows high amount of C
which were present undiluted in the metal matrix of iron.
The result looks very surprising. The high C composition in
the tube may be correlated to improper/flaw involved
during the manufacture of the tube. The results obtained
are as shown in below.
3.3.1. Pre Facture Sample
Figure 3.3.1-2: shows the graphical result of EDS analysis carried out
at certain area (Figure 3.3.1-1) of pre fractured surface.

The following is the table showing the composition of

sample tested for EDS
From the EDS analysis the presence of 3.23 percentage
by mass indicates its high carbon steel. The presence of
remaining alloys quantity was found to be less. By the
composition the alloy is brittle in nature.
3.3.2. Post Fracture Sample

Figure 3.3.1-1

Figure 3.3.2-1

Figure 3.3.2-2: shows graphical result of EDS analysis carried out at

certain area (Figure 3.3.2-1) of fractured surface

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Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 9, September 2014)
2. The microstructure of the pre fractured surface sample
was observed, the grains are not uniform and it was
heterogeneous state. The fractured surface also
observed through SEM, showed the presence oxides.
3. By the composition analysis it was found that due to
increase in the carbon percentage in the material at
fractured surface, the samples brittleness was
increased. The carbon percentage was increased due
to environmental condition, may be due to entrapment
of carbon particles concentrated at the fractured
surface, failed component might have kept open for
longer duration and the type of impact load. Hence
component failed as brittle facture.

Table showing percentage by mass of composition of

post fractured sample
EDS analysis shows the carbon content increased from
13.38% to 65.34% by atomic weight stating that materials
brittleness was increased at fractured surface of the
component, hence the sample has undergone brittle
fracture.

REFERENCES
[1]
[2]
[3]

IV. CONCLUSION

[4]

It is concluded from the study of failed fork tube of

motorcycle are:
1. The sequence of failure of the fork tube due to sudden
impact loading was initially bent due to its elasticity,
and then crack was initiated and propagated, to
fracture.

[5]
[6]

612

The effect of vehicle roadworthiness on crash incidence and severity

by George Rechnitzer, Narelle Haworth, Naomi Kowadlo.
SEM in failure analysis by Shaiful Rizam Shamsudin, Bangi, 43000
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Material science and engineering An Introduction by William D.
Callister, Jr. published by John wiley & sons, Inc.
Introduction to Scanning Electron Microscope -theory, practice, &
procedures by Micheal Dunlap and Dr. J.E. Adaskaveg.
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Failure analysis of engineering structuresMethodology and Case
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