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Boca Bearings . Modefo's RC Helicopters . XHELI.COM

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Safety - RC Helis are not toys > Servo Arm failures!
 
 
Derek Round
Heliman
Location: Bradford, UK

Having experienced a couple of servo arm failures over the years. And had one today. This time decided to have a good look at the failure! The tail servo arm broke clean off, halfway between the clevis attachment hole and the centre of the arm, naturally in flight, and of course the heli went into a violent piro, but managed to land it with no damage, phew!
Interesting failure though! On inspection, it appears to be a classic example of a "fatigue" crack, starting from some sort of stress raiser, and getting progressively larger and larger until the very small amount of plastic left fails.
As an engineer, I'm very familiar with this sort of failure in metal, but I've never heard of it in plastic!! Always thought that a necessary criteria for a fatigue failure was the ability of the material to "work harden". Does nylon work harden?
Any comments from those intelligent folks out there?
Thanks in anticipation.
Derek.
03-25-2005 Over year old.
 
 
zoom boy
Key Veteran
Location: N.E. Lincolnshire UK

All a fatigue crack needs is the part is subjected to a on/off load past its elastic range, it will be even worse if there is a pre-existing crack which can open up that small crack until the part is compromised to the point where it will just snap, anything solid can suffer a fatigue crack, it doesnt have to be metal

Just replace all the references to metal in this link with plastic

http://www.mcnallyinstitute.com/CDweb/f-html/f008.htm

This is why I use the big circular servo horns when ever possible, more material and the stress is spread out over a larger area
03-25-2005 Over year old.
 
 
Derek Round
Heliman
Location: Bradford, UK

Thanks for the suggestion "zoom boy" for using big circular horns. Guess what I've replaced the broken horn with?
Thanks again,
Derek
03-26-2005 Over year old.
 
 
PacketStorm
Senior Heliman
Location: Atlanta, GA - USA

Derek, I'm also an engineer and puzzled by what the source of the initial crack was. I know polycarbonate materials are subject to crazing when exposed to certain chemicals, but nylon is pretty inert to chemical exposure. That is, assuming the servo arm is *pure* nylon.

Is there any possibility of some compound getting on your servo arm that would have initated the crack? A lot of people get freaked out when you put blue loctite on the little nut that holds the ball on the servo arm because they say it causes the plastic to break down. Personally I've never experienced this, and I always use blue loctite on that little nut.

Just something to think about....

I need to look up nylon and see if there are any chemicals that cause embrittlement with it.

You fly...you crash...it's life
04-01-2005 Over year old.
 
 
PacketStorm
Senior Heliman
Location: Atlanta, GA - USA

Well, I just did some quick research and found that nylon has been determined to become brittle when it "dries out." I know from past work experience that nylon absorbs moisture from the air - at the same time it changes dimensions - it swells. It actually changes it's dimensions in the same way a metal part does when heated - ie. a doughnut shaped part will have a larger OD and a larger ID when exposed to moisture. It also becomes more elastic.

Conversely, if exposed to overly dry air it will dessicate and shrink. Also, UV exposure does bad things to nylon. If this particular link had been around for some time and exposed to the sun a lot, maybe that is what caused the failure....

Anyone else?

You fly...you crash...it's life
04-01-2005 Over year old.
 
 
Derek Round
Heliman
Location: Bradford, UK

Packetstorm......thanks for your constructive comments!
The horn in question had been cut down from those "multi-horns" with six "arms" that are supplied with the servo, to leave an arm on each side. There are a series of flats around the hub of the horn, the marks left after the unrequired horns were removed from the six armed original. So there could easily have been some sort of "stress raiser" left at the root! Only one side was used, and the connector was a specialised one, like a ball end, but where piano wire (epoxied to the carbon push rod) was clamped in it by a screw. Interestingly both the clamping screw, and the two nuts on the other end had been treated with loctite!
And again, thanks for your comments about UV degradation.....the servo is mounted on the boom, just behind the mast, and is fully exposed to light! So maybe thats a factor as well?
I do remember being told years ago, that with an old nylon prop, it was a good idea to boil it in water for some time, to reduce the possibility of brittle fracture....it had not occurred to me that it might be worthwhile to do it to to servo horns.
Once again Packetstorm, thanks for those enlightening comments!
And any more comments out there?
Derek
04-02-2005 Over year old.
 
 
CBenslay
Heliman
Location: Fishers, Indiana

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Also, UV exposure does bad things to nylon. If this particular link had been around for some time and exposed to the sun a lot, maybe that is what caused the failure....
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PacketStorm,

Maybe we need to put sunscreen on our servo arms too! I'm a redhead and have plenty of sunscreen to spare if anyone needs any.

Chuck
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Newbie learning to hover!
Raptor 30v1, XP8103
04-03-2005 Over year old.
 
 
PacketStorm
Senior Heliman
Location: Atlanta, GA - USA

Quote 
Maybe we need to put sunscreen on our servo arms too! I'm a redhead and have plenty of sunscreen to spare if anyone needs any.




All I've got is bug repellant.

You fly...you crash...it's life
04-03-2005 Over year old.
 
 
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Safety - RC Helis are not toys > Servo Arm failures!
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