Reliability Design of Mechanical Systems Such as Compressor Subjected to Repetitive Stresses

This study demonstrates the use of parametric accelerated life testing (ALT) as a way to recognize design defects in mechanical products in creating a reliable quantitative (RQ) specification. It covers: (1) a system BX lifetime that X% of a product population fails, created on the parametric ALT scheme, (2) fatigue and redesign, (3) adapted ALTs with design alternations, and (4) an evaluation of whether the system design(s) acquires the objective BX lifetime. A life-stress model and a sample size formulation, therefore, are suggested. A refrigerator compressor is used to demonstrate this method. Compressors subjected to repetitive impact loading were failing in the field. To analyze the pressure loading of the compressor and carry out parametric ALT, a mass/energy balance on the vapor-compression cycle was examined. At the first ALT, the compressor failed due to a cracked or fractured suction reed valve made of Sandvik 20C carbon steel (1 wt% C, 0.25 wt% Si, 0.45 wt% Mn). The failure modes of the suction reed valves were similar to those valves returned from the field. The fatigue failure of the suction reed valves came from an overlap between the suction reed valve and the valve plate in combination with the repeated pressure loading. The problematic design was modified by the trespan dimensions, tumbling process, a ball peening, and brushing process for the valve plate. At the second ALT, the compressor locked due to the intrusion between the crankshaft and thrust washer. The corrective action plan specified to perform the heat treatment to the exterior of the crankshaft made of cast iron (0.45 wt% C, 0.25 wt% Si, 0.8 wt% Mn, 0.03 wt% P). After these design modifications, there were no troubles during the third ALT. The lifetime of the compressor was secured to have a B1 life of 10 years.