Impact Factor (2025): 6.9
DOI Prefix: 10.47001/IRJIET
Connecting
rod bolts are critical fasteners in heavy equipment diesel engines, where their
structural integrity is paramount for operational reliability. This study
investigates the root cause of a connecting rod bolt fracture in a heavy
equipment diesel engine which have 936 Horsepower, which precipitated a
catastrophic engine breakdown involving low power, overheating, and oil
leakage. The failure analysis employed visual observation, macrographic
examination, and Vickers micro-hardness testing to evaluate the fracture
morphology and material properties. Hardness testing results revealed a core
hardness of 347 HV, confirming that the bolt material (AISI 8640) retained a
proper tempered martensite structure consistent with standard specifications,
thereby ruling out material deficiency or thermal degradation. Macrographic
analysis identified a progressive failure sequence involving two distinct
mechanisms. The primary bolt failed via High Cycle Fatigue (HCF), evidenced by
a flat fracture surface and ratchet marks at the periphery, indicative of
reversed bending forces. The fracture of the primary bolt caused a loss of
clamping force, leading to the instantaneous failure of the remaining bolts via
ductile overload, characterized by fibrous topography and shear lips. The study
concludes that the root cause of the failure was mechanical joint instability
(loosening), which introduced fatal bending stresses and initiated the fatigue
mechanism.
Country : Indonesia
IRJIET, Volume 10, Issue 3, March 2026 pp. 58-62