Failure Analysis of the Stacker Crawler Chain Link

AbstractStacker ARs 2000 presents the final link in the system for continuous overburden removal in the open pit mine “Kostolac” – Serbia. Its superstructure leans on three crawlers of the same length, width and height. During the stacker's travel from the erection site to the open pit mine, three crawler chain links fractured, presenting an indication of the problems that were to occur during exploitation. In fact, after only 1000 working hours (about three months), 30 chain links sustained fractures resulting in direct and indirect costs due to the downtime that substantially diminished the effects of the overburden removal system. The goal of the study presented in the paper was to diagnose the cause of chain link breakdown occurrence. Working stresses in the chain link are defined by applying FEM. Experimental investigations define the chemical composition, the tensile properties, the impact toughness and the macro and microhardness. Metallographic examinations are conducted additionally. Based on the results of the numerical-experimental analysis, it can be concluded that chain link breakdown is predominantly caused by (a) substantial deviation of the mechanical properties of the material with respect to those prescribed by the standard and (b) the existence of macro and microcracks in the material structure