Fatigue failure analysis of washing machine top frame under cyclic loading – an investigative study in mitigating market complaint

This study paper looks into the structural integrity and failure mechanisms of washing machine top frames, with the goal of improving household appliance durability and reliability. Critical regions prone to fatigue failure were identified using SolidWorks software. Stress analysis and deformation analysis revealed the failure prone areas but upon assessing the costs associated with designing new molds for modified design and performing the breakeven calculation, we decided to go with an approach of using an alternate material which will not cause any change in existing mold. Polycarbonate (PC) with 50% long glass fiber reinforcement, were investigated to improve fatigue resistance. A new top frame of this material was made along with existing material ABS. Testing on a door simulator machine demonstrated a considerable improvement in durability, with the PC-based top frame demonstrating a 1128% increase in cycle endurance over the ABS counterpart. Top frame made up of ABS broke after 297 cycles and PC with 50% long glass fiber top frame broke after 3697 cycles. These findings highlight the significance of systematic design optimization and material selection for assuring long-term performance and safety in washing machine top frames.