Failure Analysis of Power Steering Gearbox Housing in 2500 CC Diesel Car

Sri Nugroho; Yusuf Umardani; Maulana Zaky Cahyadi

doi:https://doi.org/10.47001/ICJES/2025.411003

Authors

Sri Nugroho

Dept. of Mechanical Engineering, Diponegoro University, Jl. Prof. Sudarto No. 13, Tembalang, Kec. Tembalang, Semarang, Central Java 50275, Indonesia

Yusuf Umardani

Dept. of Mechanical Engineering, Diponegoro University, Jl. Prof. Sudarto No. 13, Tembalang, Kec. Tembalang, Semarang, Central Java 50275, Indonesia

Maulana Zaky Cahyadi

Dept. of Mechanical Engineering, Diponegoro University, Jl. Prof. Sudarto No. 13, Tembalang, Kec. Tembalang, Semarang, Central Java 50275, Indonesia

Abstract

The power steering gearbox housing is one of the components in a car that functions as a coupling and directional force converter between the steering wheel and the front wheels of the car. This component experienced failure in the form of fracture. This study aims to determine the failure mechanism, material characteristics, and loading mechanism through failure analysis. The testing methods used were visual observation, chemical composition testing, metallographic testing, hardness testing, and Finite Element Method (FEM) simulation using SOLIDWORKS 2025 software. Visual observation results show that the failure that occurred led to the phenomenon of fatigue failure, which is characterized by crack initiation, final crack zone, and ratchet marks. Metallographic testing shows that the material has nodular graphite with a ferrite + pearlite matrix, indicating that the material is nodular cast iron. Hardness testing showed a value of 194-221 HV. Composition testing revealed the presence of nodulizer components, namely Mg and Ce. The FEM simulation results show that the peak stress for the 4-bolt model is 259.3 MPa and for the 3-bolt model is 288.2 MPa. The 3-bolt model is unsafe because the peak stress value is higher than the material fatigue margin.

Keywords

Failure analysis fatigue failure Finite Element Method power steering gearbox housing nodular cast iron

Citation of this Article

Sri Nugroho, Yusuf Umardani, & Maulana Zaky Cahyadi. (2025). Failure Analysis of Power Steering Gearbox Housing in 2500 CC Diesel Car. International Current Journal of Engineering and Science (ICJES), 4(11), 14-19. Article DOI: https://doi.org/10.47001/ICJES/2025.411003

References

Aji, W. S., & Nugroho, S. (2014). Analisis Kegagalan Baut Pengikat Gearbox Pada Lokomotif Kereta Rel Diesel Elektrik (Krde). Jurnal Teknik Mesin, 2(4), 413-420.
Wei, C., Shi, J., Sun, Y., Yang, Y., Du, M., & Cao, H. (2025). Analysis of vibration signal transmission and power loss in complex nonlinear dynamics interfaces within gearbox systems. Mechanical Systems and Signal Processing, 234, 112850.
Ihlas, A., Puspita, D. F., & Tjahjohartoto, B. (2018). Investigasi Fraktografi dan Analisa Tegangan pada Kerusakan Baut M64 Grade 10, 9 yang Mengalami Pengencangan Berlebih. Jurnal Teknologi Bahan dan Barang Teknik, 8(1), 9-18.
Bhardwaj, A., Slavin, D., Walsh, J., Freudenberg, J., & Gillespie, R. B. (2020). Rack force estimation for driving on uneven road surfaces. IFAC-PapersOnLine, 53(2), 14426-14431.
Asi, O. (2006). Failure analysis of a crankshaft made from ductile cast iron. Engineering Failure Analysis, 13(8), 1260-1267.
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Hu, W., Liu, Z., Liu, D., & Hai, X. (2017). Fatigue failure analysis of high-speed train gearbox housings. Engineering Failure Analysis, 73, 57-71.
Mason, P. W., Brandenburg, K. A., & Hornbach, D. J. (2016). Improving Fatigue Life of Ductile Cast Iron via Surface Enhancement.
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[1] Aji, W. S., & Nugroho, S. (2014). Analisis Kegagalan Baut Pengikat Gearbox Pada Lokomotif Kereta Rel Diesel Elektrik (Krde). Jurnal Teknik Mesin, 2(4), 413-420.

[2] Wei, C., Shi, J., Sun, Y., Yang, Y., Du, M., & Cao, H. (2025). Analysis of vibration signal transmission and power loss in complex nonlinear dynamics interfaces within gearbox systems. Mechanical Systems and Signal Processing, 234, 112850.

[3] Ihlas, A., Puspita, D. F., & Tjahjohartoto, B. (2018). Investigasi Fraktografi dan Analisa Tegangan pada Kerusakan Baut M64 Grade 10, 9 yang Mengalami Pengencangan Berlebih. Jurnal Teknologi Bahan dan Barang Teknik, 8(1), 9-18.

[4] Bhardwaj, A., Slavin, D., Walsh, J., Freudenberg, J., & Gillespie, R. B. (2020). Rack force estimation for driving on uneven road surfaces. IFAC-PapersOnLine, 53(2), 14426-14431.

[5] Asi, O. (2006). Failure analysis of a crankshaft made from ductile cast iron. Engineering Failure Analysis, 13(8), 1260-1267.

[6] Aliakbari, K., Nejad, R. M., Mamaghani, T. A., Pouryamout, P., & Asiabaraki, H. R. (2022). Failure analysis of ductile iron crankshaft in compact pickup truck diesel engine. In Structures (Vol. 36, pp. 482-492). Elsevier.

[7] Hu, W., Liu, Z., Liu, D., & Hai, X. (2017). Fatigue failure analysis of high-speed train gearbox housings. Engineering Failure Analysis, 73, 57-71.

[8] Mason, P. W., Brandenburg, K. A., & Hornbach, D. J. (2016). Improving Fatigue Life of Ductile Cast Iron via Surface Enhancement.

[9] Vander Voort, G. F., Lampman, S. R., Sanders, B. R., Anton, G. J., Polakowski, C., Kinson, J., ... & Scott Jr, W. W. (2004). ASM handbook. Metallography and microstructures, 9, 44073-0002.

[10] Standard, A. S. T. M. (1985). A247. Annual Book of ASTM Standards, 1.