Failure analysis of conveyor pulley shaft

• A failure analysis was performed on the shaft of a conveyor belt drive pulley.
• The shaft failed after seven days in service.
• Failure mechanism was high cycle fatigue.
• Failure occurred due to improper reconditioning of the shaft.

The shaft of a conveyor belt drive pulley failed in service. An investigation was performed in order to determine the failure root cause and contribution factors. Investigation methods included visual examination, optical and scanning electron microscope analysis, chemical analysis of the material and mechanical tests. A finite element analysis was also performed to quantify the stress distribution in the shaft. It was concluded that the shaft failed due to fatigue and that the failure was caused by improper reconditioning of the shaft during routine overhaul.