Failure Analysis of Cylinder Used In a Car Flipper Device

Faisal Khan; Altaf Gafoor

doi:10.51501/jotnafe.v39i2.842

Authors

Faisal Khan NAFE, NSPE, PEO https://orcid.org/0000-0002-4179-0593
Altaf Gafoor https://orcid.org/0000-0001-9314-2670

DOI:

https://doi.org/10.51501/jotnafe.v39i2.842

Keywords:

Kinematics, finite difference, impact energy, numerical methods, cylinder cap, kinematics, finite difference, fracture, impact energy, metallurgical investigation, numerical methods, pneumatic piston travel speed, forensic engineering, car flipper device

Abstract

A car flipping device is a special effects aid used to flip cars in the production of movies and television shows. The device uses a pivoting arm that moves under the stroke of a cylinder powered by compressed ni-trogen. In a trial run of the device, the cylinder’s piston broke through the cylinder cap. A kinematic analysis developed a parametric mathematical model of the motion of the cylinder arm and piston, which formed the basis for a finite difference analysis to determine the speed of the cylinder’s piston at the end of its stroke. Metallurgical testing was conducted on the broken cylinder to determine the stress-strain characteristics, im-pact resistance, and Scanning Electron Microscopy (SEM) used to examine the fracture surface. The analysis determined that the kinetic energy of the piston was adequate to cause yielding of the cylinder but not rupture. Continued usage degraded the impact resistance available until rupture occurred.

References

J. McCarthy, An Introduction to Theoretical Kinematics, Cambridge: MIT Press, 1990, p. Chapter 1.

Crane, Flow of Fluids Technical Paper 410M, New York: Crane Company, 1982, p. Chapter 1.

M. R. Lindeburg, PE Civil Reference Manual, Sixteenth Edition, Belmont: Professional Publications Inc., 2018, p. Chapter 17.

S. C. R. Chapra, Numerical Methods for Engineers, Sixth Edition, New York: McGraw-Hill Companies Inc., 2010, p. Chapter 6.

R. Mortimer, Physical Chemistry Third Edition, London: Elsevier Academic Press, 2008, p. Chapter 1.

R. LeVeque, Finite Difference Methods for Ordinary and Partial Differential Equations, Seattle: Society of Industrial and Applied Mathematics, 2007, p. Chapter 1.

R. Hibbler, Mechanics of Materials, 6th Edition, New Jersey: Prentice Hall, 2004, p. Chapter 14.

A. Liu, Mechanics and Mechanisms of Failure: An Introduction, Ohio: ASM International, 2005, p. Chapter 2.

ASM International, Steel Castings Handbook, 6th Edition, ASM International, 1995, p. Chapter 23.

ISO, Safety devices for protection against excessive pressure Part 1 - Safety Valves, ISO, 2004, p. Chapter 8.