Detecção precoce de falhas em garfos traseiros de motocicletas utilizando o método FMEA: um estudo de caso.

Abstract

This study aimed to apply the Failure Mode and Effects Analysis (FMEA) method to the early detection of failures in motorcycle swingarms, seeking to improve structural reliability and minimize operational risks. The research combined bibliographic, experimental, and statistical approaches, involving fatigue tests, liquid penetrant inspections, and data acquisition systems for strain monitoring. The results demonstrated that the root cause identified was excessive burr in the mounting hole, and the corrective actions successfully reduced the Risk Priority Number (RPN) from 400 to 80 (an 80% reduction). The application of the FMEA method allowed the classification of failures by severity, occurrence, and detection, resulting in risk priority numbers (RPN) which indicated the need for revisions to stamping tooling and the implementation of strict dimensional inspection criteria. Preventive measures such as process standardization and critical variable control proved effective in mitigating potential failure modes. It is concluded that integrating mechanical testing with the FMEA method provides a reliable and cost-effective tool to enhance the safety and durability of motorcycle components.