CHAPTER 5

CONCLUSION AND RECOMMENDATION

5.1 Introduction

This chapter summarizes all the results obtained from this study and indicates that the

objective and the scope of the project are accomplished.

5.2 Conclusion

A series of experiments and simulation was carried out in order to investigate the

failure characteristic of constant force spring on Starburst LML counterweight balancing

mechanism. The constant force spring failed at the center of constant force spring tangential

to the smaller mandrel.

The maximum torque that applied to the constant force spring when it is in the

maximum deflection is 62672 Nmm which is much lower than the maximum design torque,

1335496.2 Nmm. This shows that the torque applied to the constant force spring in Starburst

LML counterweight balancing mechanism is acceptable.

Visual inspection and macroscopic examination of the fracture surface of the constant

force spring revealed the direction of crack propagation and several beach marks. Result from
metallographic examination showed there were macrocracks on grain boundaries. These

macrocracks most probable result of stress concentration in that area.

The hardness test shows that the microhardness at the location near to the fracture area

is lower than at a location far from the fracture area. It is believed that the fracture has

negatively affected the microhardness of the constant force spring.

Image from SEM revealed multiple porosities which is most probably the point of

crack initiation. Image from SEM also revealed the fatigue striations on the fracture surface of

the failed constant force spring. These features are the evidence that the constant force spring

had failed due to fatigue failure.

Based on the simulation carried out, it can be concluded that the constant force spring

has not yielded as the maximum Von Mises stress obtained is 455.6 Mpa. The yield stress of

the material is 520 MPa. However the stress analysis has given an indication that the stress

concentration at the center of constant force spring tangential to the smaller mandrel is higher

compared to the other areas of constant force spring.

The result obtained from the simulation showed that there is only small displacement

occurred in the constant force spring. The maximum displacement is 1.19644 mm.

Result obtained from simulation of fatigue analysis showed that the minimum life of

constant force spring is 4991 cycles. This agrees with the analytical analysis result which is

4185 cycles. However it should be observed that the result obtained is only an estimation.
5.3 Recommendation

From the findings of this study, the following recommendations were proposed to

avoid similar failures in future:

a) Regular inspection of the Starburst LML counterweight balancing mechanism to

detect the cracks on constant force spring.

b) The constant force spring should be changed after the estimation cycles to failure.

c) Rest position of the Starburst LML should be changed from -8° depression to 45°

elevation in order to avoid the constant force spring to be the maximum deflection

during the rest position.

In order to improve the investigation of failure characteristics on the constant force

spring on Starburst LML counterweight balancing mechanism, a few factors must be

considered.

The study is conducted with the constant force spring analyzed as single layer which

may have affected the result of the simulation. To improve the study, it is essential that the

constant force spring is analyzed as a layered spring pack

In addition, experimental procedures on the fatigue life of the constant force spring in

the real situation need to be conducted to verify the simulation result.