RETURN

ME104
Crack Formation in Generator Connecting Rod Serrations
Technical committee

1. Outline of breakdown

While the ship was docked for Intermediate survey, overhaul inspection of generator diesel revealed crack
formation in all connecting rod serrations of the three generators aboard. The cracks were all found at the
upper section of the upper serration teeth.
All connecting rods (18) were replaced with new parts.

2. Cause

The following factors are considered as a possible cause.

1) Insufficient material strength
2) Insufficient processing accuracy
3) Decrease in tightening torque
For 1), test results revealed no problems. The surface roughness of the teeth was 18S for damaged
parts as against 6S in specification. The contact surface of the teeth was not even and indication of strong
contact was observed in certain local sections. Also, chamfering of the teeth was insufficient. In addition,
the measurement of a torque with which a damaged part was tightened to the index mark showed that the
torque had fallen to a range of 47 to 59 kgm. (Specified torque was 60 to 65 kgm.)

3. Countermeasure

<Ship Countermeasure>
1) To increase the rod bolt tightening torque.
To change it from 65 - 70 kgm to 70 - 75kgm.
2) Perform dye penetrant test of the serration in 3000 hours.
3) Perform dye penetrant test of the serration in 4000 hours.
4) Perform magnetic inspection of serrations after 4000 hours, on removal of piston.
<Maker Countermeasure>
1) Increase processing accuracy to improve tooth bearing (lapping)
2) Improve surface roughness (processing method)
3) Improve tooth root roughness (Roll processing at R section)
The parts will be replaced with improved parts as they are prepared.

1
The Marine Engineer Feb.1989