Comprehensive Analysis of Needle Bearing Failures in Fuel Transfer Pumps: Insights from Testing and Finite Element Analysis

<div>This study investigates the failure mechanisms of needle bearings within fuel transfer pump assemblies through a comprehensive approach combining endurance testing, detailed inspection, the Dykem blue method, proximity sensors, and finite element analysis (FEA). The findings reveal critical insights into the causes of failure, highlighting significant axial displacement, with a maximum of 0.37 mm measured by proximity sensors. The Dykem technique identified distinct wear patterns across various components, pinpointing areas of high stress and potential failure. Detailed bearing inspections uncovered trunnion damage and abrasive wear, corroborated by FEA, which quantified displacements of 0.144 mm in the x-direction, 0.030 mm in the y-direction, and 0.015 mm in the z-direction. The primary operational factors contributing to bearing failure were contamination and inadequate axial control. These insights are pivotal, as they align with and expand upon established literature on bearing failures, providing a deeper understanding of the interplay between mechanical wear and operational conditions. Despite the robustness of the methodology, challenges included ensuring the accuracy of axial displacement measurements and replicating real-world operational stresses in a controlled environment. The study proposes several recommendations to enhance axial support and optimize system design to mitigate the identified issues. The societal impact of this research is significant, offering potential improvements in machinery reliability, which can lead to enhanced industrial efficiency and safety standards. This work advances the current knowledge in the field and provides practical solutions for extending the lifespan and performance of critical mechanical components in fuel transfer systems.</div>