Failure of the bucket wheel excavator buckets

Abstract Buckets are a vital substructure of all digging machines, and are intended for the realisation of the fundamental machine function - soil excavation. This paper presents the results of the experimental-numerical investigation of the cause of the bucket wheel excavator SRs 470 buckets failure. The chemical composition and mechanical properties, the impact toughness, hardness, tendency to cracks and the microstructure were determined using appropriate tests. Experimental examinations of working and residual stresses were performed using strain gauges. The superposition of the experimentally determined working and residual stresses and the calculation of the total principal stresses were conducted using the originally developed procedure presented in this paper. The bucket working stress state was calculated by applying the linear finite element method. Conclusions based on the investigation results show that the main reasons for the buckets failure were the ‘design-in defects’ - oversights made during the procedures of geometrical shaping and material selection. Furthermore, high values of residual stresses, as well as the cold cracking observed on the welded joint of the knife and the bucket body, suggest that the ‘manufacturing-in defects’ also played a significant role in the failure. The superposition of influences of the ‘design-in defects’ and the ‘manufacturing-in defects’ has conditioned the appearance and propagation of long-term fatigue cracks, leading to the total destruction of the buckets. The fact that buckets' failure appeared due to oversights made during geometrical shaping, material selection and manufacturing further points to the importance of the critical approach implementation during the design phase of the earthmoving machines working devices.