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.
