Failure analysis of vise jaw holders for hacksaw machine

Failure analysis in mechanical components has been investigated in many studies in the last few years. Failure analysis and prevention are important functions in all engineering disciplines. Materials engineers are often the lead role in the analysis of failures, where a component or product fails in service or if a failure occurs during manufacturing or production processing. In any case, one must determine the cause of the failure to prevent future occurrences and/or to improve the performance of the device, component or structure. For example, the vise jaw holders of hacksaws can break due to accidental heavy loads or machine misuse. The parts that break are the stationary and movable vise jaw holders and the connecter power screw between the holders. To investigate the failure of these components, a three-dimensional finite element model for stress analysis was performed. First, the analysis identified the broken components of the hacksaw machine. In addition, the type of materials of the broken parts was identified, a CAD model was built, and the hacksaw mechanism was analyzed to determine the accurate applied loads on the broken parts. After analyzing the model using Abaqus CAE software, the results showed that the location of the high stresses was identical with the high-stress locations in the original, broken parts. Furthermore, the power screw was subjected to a high load, which deformed the power screw. Also, the stationary vise jaw holder was broken by impact because it was not touched by the power screw until the movable vise jaw holder broke. A conclusion is drawn from the failure analysis and a way to improve the design of the broken parts is suggested.