Rolling element bearings are common in any rotating machinery. They are subjected to failure under continuous running therefore they have received a great deal of attention in the field of condition monitoring. Machinery vibration monitoring programs are e ffective in reducing overall operating cost of industrial plant. Monitoring vibration levels over time allows the plant engineer to predict the problems before serious damage and avoid the shutdown of plant. When pending problems are discovered early the p lant engineer has the opportunity to schedule maintenance and reduce down time in a cost effective manner. Vibration analysis is used as a tool to determine machine condition and find specific location of machinery problems. This expedites repairs and mini mizes cost. In rolling element bearings,contamination of lubricant grease by solid particles is one of the several reasons for an early bearing failure. In this respect,this project work deals with the effect of contamination of lubricant by solid partic les on the dynamic behavior of rolling bearings. Generally different materials such as Silica,metal - burr,dolomite - powder,and iron - ore,all at three concentration levels and different particle sizes were used to contaminate the lubricant.
This document summarizes a study that used Taguchi methodology to examine the effect of die casting process parameters on porosity levels in aluminum alloy SAE 308. An experiment was conducted using an L9 orthogonal array to test combinations of four process parameters (first phase speed, second phase speed, first phase length, and injection pressure) at three levels. Porosity measurements were taken for each sample and analyzed. ANOVA results showed injection pressure had the greatest effect on porosity levels at 43.64%, followed by first phase length at 28.39%. Predicted porosity levels and a 95% confidence interval were also estimated based on the optimal parameter settings.
Review on investigation and optimization of turning process parameter in wet ...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
The big challenge of the mass production firms is concentrated for achieving high quality
products with good dimensionability with high productivity, less wear on the cutting insert, less use
of cutting fluid, within less time. This paper present dissertation work of an investigation of turning
process parameters on hard EN 31 material, for optimization of surface roughness, material removal
rate, machining time in wet and minimum quantity lubrication system. The experiment is carried out
by considering four controllable input variables namely cutting speed, feed rate, depth of cut and
insert nose radius in the presence of wet & MQL system. This experiment also present the relation
between chip formations and controllable variables along with chip thickness, chip colors & chip
velocity from which its effect on insert wear, quality of product can be easily found out, because of
chip morphology gives indirectly the effect of it on the insert wear. In this dissertation work
minimum quantity lubrication system is used for reducing the cutting zone temperature properly and
very fastly. Finally comparison is carried out between wet and minimum quantity lubrication system
from which one can easily identify which system is better for higher productivity along with high
surface finish. This work also present the productivity (MRR) concept in production. The design of
experiment and optimization of surface roughness, material removal rate, machining time is carried
out by using response surface methodology (RSM). Central composite design method is used (CCD)
for the total experimental design work and its analysis and also for optimization of turning process
parameter by which wastage of the machining time, power can be avoided.
A Review on Modification in Honing Machine Stone Feeding InstallationIRJET Journal
This document summarizes a review on modifications made to the stone feeding installation on a honing machine. Honing is used to finish bearing surfaces and requires tool wear compensation to maintain surface finish quality during mass production. The existing manual stone feeding system was replaced with an automated mechanism using a ball screw actuator and stepper motor. This reduced human errors from operators and increased the number of bearing rings that could be honed. The review covers literature on tool wear monitoring methods like ultrasonic testing and sensor fusion, as well as tool wear prediction modeling. It was concluded that the new automated stone feeding system achieved the objectives of compensating for tool wear and improving honing machine productivity.
IRJET- Experimental Analysis and Geometrical Effect on Mild Steel with Un...IRJET Journal
This document describes an experimental analysis of drilling mild steel with both uncoated and tungsten carbide coated high-speed steel drill bits using the Taguchi technique. The experiment analyzed the impact of drilling speed, feed rate, and depth of cut on surface roughness, hole diameter, and material removal rate. Experiments were conducted on a CNC milling machine without cutting fluid. Results for the uncoated and coated drilling were collected and analyzed using Minitab software to determine the optimal drilling parameters.
Investigating the effect of machining parameters on surface roughnessIAEME Publication
This document summarizes a study that used Design of Experiments (DOE) and Analysis of Variance (ANOVA) to investigate the effects of machining parameters on the surface roughness of 6061 aluminum alloy during end milling. The parameters examined were cutting speed, depth of cut, and feed rate. The study found that feed rate had the most significant impact on surface roughness based on ANOVA results. The optimal parameters for a smooth surface were a cutting speed of 500 rpm, depth of cut of 1.2 mm, and feed rate of 15.33 mm/min.
Optimizing of High Speed Turning Parameters of Inconel 625 (Super Alloy) by u...IRJET Journal
This document discusses optimizing cutting parameters for high speed turning of Inconel 625 super alloy using the Taguchi technique. Inconel 625 is difficult to machine due to its properties. The study aims to determine optimal cutting speed, feed rate, and depth of cut to minimize surface roughness and maximize material removal rate. Experiments are conducted on a CNC turning machine using tungsten carbide tools and Taguchi's L9 orthogonal array. The cutting forces and responses of surface roughness and material removal rate are measured. Regression and Taguchi design of experiments methods are used for analysis to determine the optimal cutting parameters for high speed machining of Inconel 625 super alloy.
Ch1 introduction Erdi Karaçal Mechanical Engineer University of GaziantepErdi Karaçal
Manufacturing involves applying physical or chemical processes to alter the form of materials. It can be defined technologically as altering geometry, properties, or appearance of a starting material. Economically, it is transforming materials into items of greater value through processing or assembly. Common production types include continuous, mass/flowline, batch, and one-off. The document discusses various manufacturing processes, production systems, and layouts. It provides an overview of key concepts in manufacturing and production.
Optimization of Surface Roughness Parameters in Turning EN1A Steel on a CNC L...IRJET Journal
This document summarizes an experiment to optimize surface roughness parameters when turning EN1A steel on a CNC lathe with coolant. The experiment uses Taguchi methods to design the experiment with three factors (cutting speed, feed rate, and depth of cut) at three levels each, for a total of nine experiments. Analysis of variance is used to analyze the results and determine that feed rate has the highest contribution to surface roughness at 68.56%, followed by cutting speed at 18.98% and depth of cut at 12.46%. Regression and general linear models are developed to model the relationship between the input and output parameters. The results provide optimal cutting conditions and are useful for manufacturing industries to improve surface finish.
Abrasive flow machining (AFM) is a method developed in the 1960s to polish, deburr, and finish intricate internal surfaces and passages. There are three main types of AFM: one-way, two-way, and orbital. AFM uses an abrasive media that is extruded through the workpiece to remove material and produce a very smooth surface down to Ra of 50nm. Key advantages include simultaneously deburring, radiusing, and polishing, and producing uniform results. AFM is widely used in aerospace, automotive, medical, and mold industries to improve surfaces, reduce friction, eliminate imperfections, and extend component life. Research aims to further improve monitoring and control of
Multiresponse optimization of surface grinding operation of en19 alloy steel ...IAEME Publication
This document describes an experimental study that used grey relational analysis to optimize surface grinding parameters for EN19 alloy steel using water-based nanofluids. The study considered nanofluid type (Al2O3 and CuO), nanofluid concentration (2-6%), depth of cut (5-10um), and feed rate (1000-2500mm/min) as process parameters. Multiple responses including surface roughness, temperature, grinding wheel wear, and material removal rate were measured. Grey relational analysis was used to convert the multi-response optimization into a single response problem to simplify the optimization. Analysis of variance was conducted to determine significant process parameters affecting the grey relational grade. The optimal levels of parameters were selected and a confirmation
IRJET- Experimental Investigation and Optimization of Process Parameters in A...IRJET Journal
The document describes an experimental investigation into optimizing the process parameters of an abrasive water jet machine. It discusses using the Taguchi method to optimize parameters like abrasive flow rate, nozzle diameter, pressure, and standoff distance to maximize material removal rate and minimize kerf width. Experiments were conducted using an L9 Taguchi array to test different parameter levels. Analysis of variance and response tables were used to analyze the results and determine the most influential parameters, with abrasive flow rate found to have the biggest effect on material removal rate and all parameters found to have little effect on kerf width.
Wally s3 e cold_rolling_mills_strip_processing_linesWally Heydendael
This document discusses recent technologies in cold rolling mills to improve product quality, as presented by SMS Demag AG. It describes Edge Drop Control systems that help achieve constant strip thickness across the width. It also details the T-roll® process technology package for simulating cold rolling processes. Furthermore, it presents a new lubrication and cleaning concept combining low-quantity lubrication with liquid nitrogen to improve strip surface quality. Online measuring systems are also discussed for documenting product quality parameters.
COMPARISON OF SURFACE ROUGHNESS OF COLDWORK AND HOT WORK TOOL STEELS IN HARD ...ijmech
The hard turning process has been attracting interest in different industrial sectors for finishing operations
of hard materials at its hardened state.Surface roughness is investigated in hard turning of AISI D3 and
AISI H13 steels of same hardness 62HRC. In this paper, an attempt has been made to model and predict
the surface roughness in hard turning of AISI D3 and AISI H13 hardened steels using Response Surface
Methodology (RSM). The combined effects of three machining parameters such as cutting speed, feed rate
and depth of cut are investigated for main performance characteristic that is surface roughness. RSM
based Central Composite Design (CCD) is applied as an experimental design. Al2O3/TiC mixed ceramic
tool with corner radius 0.8 mm is employed to accomplish 20 tests with six center points. The acceptability
of the developed models is checked using Analysis of Variance (ANOVA).The combined effects of cutting
speed; feed rate and depth of cut are investigated using surface plots.
Abrasive flow machining is a deburring and surface finishing process that uses abrasive particles mixed in a viscoelastic medium. It can polish internal surfaces, holes, and intersecting holes. The document discusses the need for AFM, abrasive materials used, the one-way, two-way, and orbital classification methods, process parameters like pressure and abrasive size, capabilities like surface finish ranges and tolerances, and applications in aerospace, automotive, die and mold making, and medical industries to improve surfaces, reduce wear, increase performance, and extend component life.
6. journal 2016 analysis of surface roughness in hard turningichsan_madya
This document analyzes the effect of process parameters on surface roughness during hard turning of oil hardening non-shrinking steel using wiper and conventional inserts. The most significant parameter affecting surface roughness was found to be feed rate, with higher feeds producing rougher surfaces. Wiper inserts produced a 30% improvement in surface roughness compared to conventional inserts. Depth of cut and type of insert were also statistically significant, while cutting speed and nose radius were not. Wiper inserts are able to produce a more uniform roughness profile compared to conventional inserts under the same cutting conditions.
Experimental Analysis & Optimization of Cylindirical Grinding Process Paramet...IJERA Editor
As per the modern Industrial requirements, higher surface finish mechanical components and mating parts with close limits and tolerances, is one of the most important requirement. Abrasive machining processes are generally the last operations performed on manufactured products for higher surface finishing and for fine or small scale material removal. Higher surface finish and high rate of removal can be obtained if a large number of grains act together. This is accomplished by using bonded abrasives as in grinding wheel or by modern machining processes. In the present study, Taguchi method or Design of experiments has been used to optimize the effect of cylindrical grinding parameters such as wheel speed (rpm), work speed, feed (mm/min.), depth of cut and cutting fluid on the surface roughness of EN15AM steel. Ground surface roughness measurements were carried out by Talysurf surface roughness tester. EN15AM steel has several industrial applications in manufacturing of engine shafts, connecting rods, spindles, studs, bolt, screws etc. The results indicated that grinding wheel speed, work piece speed, table feed rate and depth of cut were the significant factors for the surface roughness and material removal rate. Surface roughness is minimum at 2000 r.p.m. of grinding wheel speed , work piece speed 80 rpm, feed rate 275 mm/min. and 0.06 mm depth of cut.
IRJET-Surface Roughness Modeling of Titanium Alloy GrindingIRJET Journal
This document presents a study on modeling surface roughness in the grinding of titanium alloy. It aims to develop a predictive surface roughness model that relates surface roughness values to process variables like speed and depth of cut. An analytical model is developed considering factors like elastic deflections, plowing effects, and thermal effects. MATLAB simulations are also used to model the grinding wheel profile and ground surface to directly predict surface roughness. Experimental grinding tests will be conducted to validate the results from the analytical model and simulations.
The prediction of surface roughness in finish turning of en 19 steelIAEME Publication
This document describes a study that used the Taguchi method to analyze the effects of five turning process parameters (spindle speed, pressurized coolant jet, rake angle, feed rate, and depth of cut) on the surface roughness of EN-19 steel. Experiments were conducted using an L16 orthogonal array with different parameter levels. Analysis of variance showed that spindle speed had the greatest effect on surface roughness, followed by pressurized coolant jet and rake angle. The optimal combination of parameters to minimize surface roughness was determined to be a spindle speed of 1560 rpm, pressurized coolant jet of 0.5 bar, rake angle of 40 degrees, feed rate of 0.16 mm/rev,
A study of the effects of machining parameters on surface roughness using res...IAEME Publication
This document discusses a study on the effects of machining parameters on surface roughness in end milling of EN11 alloy steel. Experiments were conducted using an L18 orthogonal array to test combinations of four factors (depth of cut, feed rate, spindle speed, coolant type) at three levels each. Surface roughness was measured after each trial. Statistical analysis using ANOVA and response surface methodology was performed on the experimental data to develop a model relating the factors to surface roughness. The goal was to determine the optimal factor levels that minimize surface roughness.
Optimization of Turning Parameters Using Taguchi MethodIJMER
Abstract: Today in manufacturing and metal industries customer satisfaction is very important to
make own place in competitive market and also to make mirror image with faith in the heart of
customer, because customer gives preference to buy good quality product. In the metal and
manufacturing industries for the product low surface roughness is very important. Lowest surface
roughness assures not only good quality but also reduces manufacturing cost. In this paper the main
objective is to study effect of cutting speed, feed rate and depth of cut on surface roughness of mild steel
in turning operation and as a result of that the combination of optimum level of factors was obtained to
get lowest surface roughness. Experiments have been conducted using Taguchi’s experimental design
technique. An orthogonal array, signal to noise ratio, and analysis of variance are employed to
investigate cutting characteristics of mild steel using high speed steel. Experimental results show that
among the cutting parameter cutting speed is the most significant machining parameter for surface
roughness followed by feed rate and depth of cut.
Taguchi method and anova an approach for process parameters 2IAEME Publication
This document presents a study that uses the Taguchi method and ANOVA to optimize the surface roughness of EN 353 steel during wet turning operations. The study examines five process parameters (depth of cut, feed rate, spindle speed, rake angle, and pressurized coolant jet) at two levels each in a 16-run orthogonal array experiment. ANOVA results show that rake angle significantly affects surface roughness. The optimal parameter settings to minimize surface roughness are identified as: depth of cut of 1.0 mm, feed rate of 0.8 mm/rev, spindle speed of 780 rpm, rake angle of 70 degrees, and pressurized coolant jet of 1.0 bar. Confirmation tests validate that these settings
Enhancing the Submersible Pump Rotor Performance by Taguchi Optimization Tech...IRJET Journal
The document describes an experimental study that used Taguchi optimization techniques to improve the surface roughness of rotor components made from silicon steel for submersible pumps. Three turning cutting parameters - cutting speed, feed rate, and depth of cut - were investigated at three levels each using an orthogonal array experiment. Analysis of variance was conducted on the surface roughness measurements to determine the most significant parameters. The results showed that cutting speed had the greatest influence on surface roughness, followed by depth of cut, while feed rate was less significant. This provides information on optimal cutting conditions for machining silicon steel rotors to reduce surface roughness.
IRJET- Experimental Investigation and Optimization of Wear Characteristics of...IRJET Journal
This document experimentally investigates the wear characteristics of cerium oxide (CeO2) nanoparticle-based nanolubricant under boundary lubrication conditions. Pin-on-disc tests were conducted using diesel engine oil with 0.2-0.4% CeO2 nanoparticles added. Taguchi and Response Surface Methodology (RSM) designs of experiment were used to analyze the effect of nanoparticle concentration, load, and sliding velocity on wear rate. RSM optimization found 0.3111% nanoparticle concentration, 5kg load, and 6m/s sliding velocity gave the minimum wear rate. Cerium oxide nanolubricant showed significantly lower wear than the base oil alone under these optimum conditions.
Experimental Analysis of Material Removal Rate in Drilling of 41Cr4 by a Tagu...IJERA Editor
In manufacturing industries the largest amount of money spent on drills. Therefore, from the viewpoint of cost and productivity, modeling and optimization of drilling processes parameter are extremely important for the manufacturing industry this paper presents a detailed model for drilling process parameter. The detailed structure includes in the model, are three parameters such as such as Spindle Speed, feed and depth of cut on material removal rate in drilling of 41 Cr 4 material using HSS spiral drill .We an effect of this three parameters on material removal rate .The detailed mathematical model is simulated by Minitab14 and simulation results fit experiment data very well In this investigation, an effective approach based on Taguchi method, analysis of variance (ANOVA), multivariable linear regression (MVLR), has been developed to determine the optimum conditions leading to higher MRR. Experiments were conducted by varying Spindle Speed, feed and depth of cut using L9 orthogonal array of Taguchi method. The present work aims at optimizing process parameters to achieve high MMR. Experimental results from the orthogonal array were used as the training data for the MVLR model to map the relationship between process parameters and MMR the experiment was conducted on drilling machine. From the investigation It concludes that speed is most influencing parameter followed by feed and depth of cut on MRR
IRJET- Multi-Objective Optimization of Machining Parameters by using Response...IRJET Journal
This document summarizes a literature review on optimization of machining parameters for turning operations. Several studies that optimized cutting speed, feed rate, and depth of cut to minimize surface roughness and maximize material removal rate are reviewed. Response surface methodology was used in many of these studies to develop models of the output responses based on the input parameters. The literature showed that feed rate typically had the greatest influence on surface roughness, while cutting speed most influenced material removal rate. This study aims to use response surface methodology to optimize machining time and maximize material removal rate during turning of EN-31 alloy steel.
Assignment of weights method for the optimization of ti n coated carbide reamingIAEME Publication
This document summarizes a research study that investigated using TiN coated carbide reaming instead of WEDM to machine cylindrical bores in electro hydraulic servo valves (EHSV). The study used an L9 orthogonal array experimental design to test the effects of reaming speed, feed rate, and allowance on surface finish and cylindricity. Assignment of weights method was used to analyze the multi-response data and identify optimal parameter combinations. The results supported selecting production parameters that meet quality and cost targets while improving process performance compared to WEDM.
Investigation of Metal Removal Rate and Surface Finish on Inconel 718 by Abra...AM Publications
Abrasive Waterjet (AWJ) cutting has proven to be an effective technology for material processing with the distinct advantages of no thermal distortion, high machining versatility, high flexibility and small cutting forces. In this paper, Taguchi robust design analysis is employed to determine optimal combination of process parameters. The Analysis of Variance (ANOVA) is also applied to identify the most significant factor. The process parameters such as pressure, transverse speed, stand of distance and abrasive flow rate are optimized to investigate their influence on Metal Removal Rate (MRR) and Surface Roughness (Ra) of Inconel. Experiments are carried out by L9 orthogonal array and the results are provided to verify this approach and credible tendencies of output parameters with respect to the input parameters are discussed, from which recommendations are made for process control and optimization.
Parametric Analysis and Optimization of Turning Operation by Using Taguchi Ap...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Gearbox Noise & Vibration Prediction and ControlIRJET Journal
This document discusses techniques for reducing noise and vibration in gearboxes. It begins by reviewing common sources of gearbox noise like transmission error between gear teeth and vibration transferred to surrounding structures. Next, it examines factors that influence gear noise like torque, speed, and tooth design properties. Methods for analyzing noise like determining transmission error and time-varying gear mesh stiffness are presented. The goal is to minimize excitations from meshing gears that cause vibration of the gearbox casing and radiate noise.
Optimization of Cutting Parameters in CNC DRILLING of P30 tool Steel by using...IRJET Journal
This document summarizes research on optimizing cutting parameters in CNC drilling of P30 tool steel using the Taguchi method. The study aims to minimize surface roughness and cutting forces when drilling P30 tool steel. Eighteen drilling trials were conducted using an L18 orthogonal array experimental design to evaluate the effects of cutting speed, feed rate, drill material, and drill diameter on surface roughness. Analysis of variance (ANOVA) and signal-to-noise ratios were used to analyze the results and identify optimal cutting conditions. The document concludes that surface roughness is mainly influenced by workpiece material, drill diameter, and cutting speed.
Optimization of input parameters of cnc turning operation for the given compIAEME Publication
This document summarizes a study that used Taguchi methods to optimize cutting parameters (spindle speed, feed rate, depth of cut) for CNC turning of an aluminum alloy component. The goals were to minimize surface roughness and dimensional variation. An L9 orthogonal array experiment was conducted, varying the three parameters at three levels each. Surface roughness and dimensional tolerance measurements were used as quality metrics. Analysis found that spindle speed most impacts dimensional variation while feed rate most influences surface roughness. The optimal combination of cutting parameters was identified to improve both surface roughness and dimensional tolerance.
The document discusses optimizing parameters for boring operations. It aims to achieve a surface finish less than 2 micrometers and bore diameter of 70 mm. Experiments were conducted varying speed, feed rate, and depth of cut. Analysis of variance and response surface methodology were used to analyze results. The optimal parameters were found to be a speed of 1000 rpm and feed rate of 100 mm/min, predicted to achieve a surface roughness of 1.843 micrometers and bore diameter of 70.005 mm. Validation experiments confirmed the predicted results were within acceptable ranges.
Optimization of surface roughness in high speed end milling operation usingIAEME Publication
This document summarizes an investigation into optimizing surface roughness in high-speed end milling of Al-Si-Mg-Fe alloy workpieces using Taguchi's method. The study used an L9 orthogonal array to experiment with cutting speed, feed rate, and depth of cut. Surface roughness was measured and ANOVA was performed. Results showed depth of cut had the strongest influence on surface roughness, contributing over 73% of the variation, while cutting speed and feed rate also significantly impacted surface roughness. Surface roughness decreased with increasing cutting speed and increased with higher feed rates and depths of cut.
Optimization of surface roughness in high speed end milling operation usingIAEME Publication
This document summarizes an investigation into optimizing surface roughness in high-speed end milling of Al-Si-Mg-Fe alloy workpieces using Taguchi's method. The study used an L9 orthogonal array to experiment with cutting speed, feed rate, and depth of cut. Surface roughness was measured and ANOVA was performed. Results showed depth of cut had the strongest influence on surface roughness, contributing over 73% of the variation, while cutting speed and feed rate also significantly impacted surface roughness. Surface roughness decreased with increasing cutting speed and increased with higher feed rates and depths of cut. Overall, Taguchi's method was able to optimize the machining parameters to minimize surface roughness.
Optimization of Cylindrical Grinding of Alloy Steel using desirability functi...IRJET Journal
1. The document summarizes research optimizing parameters for cylindrical grinding of alloy steel. It used Taguchi methods, response surface analysis, and grey relational analysis to determine optimal cutting speed, depth of cut, and feed rate to maximize material removal rate.
2. Analysis found depth of cut had the greatest influence on material removal rate, followed by cutting speed then feed rate. Confirmation tests found less than 1% error between predicted and experimental material removal rates, validating the models.
3. The optimized parameters were found to be a cutting speed of 1900 rpm, depth of cut of 0.06 mm, and feed rate of 0.04 mm/rev, achieving a maximum material removal rate of 2.816 g
IRJET- Analysis of Cutting Process Parameter During Turning of EN 31 for Mini...IRJET Journal
This document analyzes cutting process parameters to minimize surface roughness during turning of EN 31 steel. Experiments were conducted using a Taguchi design of experiments with cutting speed, feed rate, and tool nose radius as parameters. Measurements showed feed rate had the greatest influence on surface roughness, followed by nose radius. The optimal combination for minimum roughness was a feed rate of 0.025 mm/rev, nose radius of 0.8 mm, and cutting speed of 210 m/min.
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Since so many years a problem occurs in KSB Pump Va mbori for casting process i.e. cracks occurs in the castings & it is repeated one. Therefore the compan y has given opportunity to me to solve this problem . In case of steel casting there are mainly cracks & also blo w holes induced due to the casting procedure. There are many factors for the casting defects .The factor is unev en material feeding in casting & also due to the mo uld material & also the core material. These cracks finally brea k directly the component of the casting i.e. in cas e of pump the casting component is like Impeller,Volute casing & casing cover. At the time of feeding of steel material in to the casting the material is in liquid us form i.e. it i s hot material & this material is feeding into casting at the time o f feeding it develop different region of heat. At o ne side the temp is high &at other side the temp is low this also pr oduce cracks. To simulate that casting we use the M AGMA SOFTWARE for simulation & validate it using NDT.
A COMPARATIVE STUDY OF DESIGN OF SIMPLE SPUR GEAR TRAIN AND HELICAL GEAR TRAI...ijiert bestjournal
The document describes the design of a simple spur gear train and helical gear train with an idler gear using the AGMA (American Gear Manufacturers Association) standard method. Key steps of the design process include selecting input parameters, creating a preliminary drawing, selecting materials, and performing theoretical calculations to determine dimensions and check for bending and contact stresses based on AGMA equations. A comparative study is carried out to select the optimal gear train design that meets the strength requirements for the given input parameters and load conditions.
COMPARATIVE ANALYSIS OF CONVENTIONAL LEAF SPRING AND COMPOSITE LEAFijiert bestjournal
A leaf spring is a simple form of spring,commonly used for the suspension in wheeled vehicles. It is also one of the oldest forms of spring. Sometimes referred to as a semielliptical l eaf spring (SELS) it takes the form of a slender ar c-shaped length of spring steel of rectangular cross section. The centre of the arc p rovides location for the axle,while tie holes are provided at either end for attaching to the vehicle body. In the present work,a seven-leaf steel spring use d in passenger cars is replaced with a composite mu lti leaf spring made of glass/epoxy composites. The dimensions sand the num ber of leaves for both steel leaf spring and compos ite leaf springs are considered to be the same. The primary objective is to compare their load carrying capacity,stiffness and weight savings of composite leaf spring. Finally,fatigue life of steel and com posite leaf spring is also predicted using life dat a
Brimmed diffuser is collection�acceleration device which shrouds a wind turbine.For a given turbine di ameter,the power augmentation can be achieved by brimmed diffuser,p opularly known as wind lens. The present numerical investigation deals with the effect of low pressure region created by wind l ens and hence to analyze the strong vortices formed by a brim attached to the shroud diffuser at exit. Also in this analysis,a c omparative numerical prediction of mass flow rates through the wind turbine has been carried out with various types of wind lens wh ich in turn helps to optimize the torque augmentati on. It has been numerically proved that there is significant increase in the wa ke formation & vortex strength when brimming effect is added to a diffuser
FINITE ELEMENT ANALYSIS OF CONNECTING ROD OF MG-ALLOY ijiert bestjournal
The automobile engine connecting rod is a high volume production,critical component. It co nnects reciprocating piston to rotating crankshaft,transmitting the thrust of the piston to the crankshaft. Every vehicle that uses an internal combustion engine requires at least one connecting rod depending upon the number of cylinders in the engine. As the purp ose of the connecting rod is to transfer the reciprocating motion of the piston into rotary motion of the crankshaft. Connecting ro ds for automotive applications are typically manufactured by forging from either w rought steel or powdered metal. the material used f or this process is Mg-Alloy and also finite element analysis of connecting rod
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1) The document discusses improving the critical speed of the valve train in a single cylinder engine from 3600 rpm to 5000 rpm. It aims to optimize the valve spring parameters to increase the speed limit without failure of contact between components.
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ENERGY CONVERSION PHENOMENON IN IMPLEMENTATION OF WATER LIFTING BY USING PEND...ijiert bestjournal
This paper consist of working of reciprocating pump which is driven by a compound pendulum. It provide s the energy required to lift the water from a tank placed approximately several meter below the ground level. Basic application of the mechanism will be for watering the garden which will be operated by means of operation opening and closing of entrance gate. Paper consists of basic concept,design of pump and compound pendulum mecha nism and fabricationed model. The concept can also be implemented in the rural areas,having the problem of electric supply. We aim at making a prototype for providing some me an for pumping of water by the pump which requires less human efforts,conside ring cost effectiveness,easy to operate and portab le mechanism.
The IC engine has seen numerous revolutionary and e volutionary modifications in technology and design over the past few decades. The sole motto behind the modifications wa s to increase the overall efficiency of the IC Engi ne including volumetric and thermal efficiency. Recently few benchmarking techn ologies like the CRDI,MPFI,HCCI,etc. in the Otto cycle and Diesel cycle engines have created an enormous revolution in the automobile industry. In spite of these technologica l and design advances,the efficiencies are not being more than a particular l imit. However,the concept of split cycle engines has dra stically increased the overall performance in all respect. The split cycle concept basically separates the fou r strokes of the conventional cycle. The Scuderi engine one of the best-in-class engine desi gns based on the split cycle concept. The Scuderi engine works on the split cycle and gives higher efficiency than the previous split cycle engines resulting overall high perform ance. It also eliminates the problems faced by previous engines based on the spl it cycle in terms of breathing (volumetric efficien cy) and thermal efficiency. This paper throws light on the greater volumetric,thermal and overall efficiency key points related t o the Scuderi Engines.
EXPERIMENTAL EVALUATION OF TEMPERATURE DISTRIBUTION IN JOURNAL BEARING OPERAT...ijiert bestjournal
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STUDY OF EFFECT OF SOLID CONTAMINANTS IN GREASE ON PERFORMANCE OF BALL BEARING BY VIBRATIONAN ANALYSIS
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STUDY OF EFFECT OF SOLID CONTAMINANTS IN GREASE ON
PERFORMANCE OF BALL BEARING BY VIBRATIONAN ANALYSIS
Yogesharao Y. More
Dr.D.Y.Patil School of Engineering
Lohegaon, Pune, M.S, India
Prof.A.P.Deshmukh
Dr.D.Y.Patil School of Engineering
Lohegaon, Pune, M.S, India
ABSTRACT
Rolling element bearings are common in any rotating machinery. They are subjected to failure
under continuous running therefore they have received a great deal of attention in the field of
condition monitoring. Machinery vibration monitoring programs are effective in reducing overall
operating cost of industrial plant. Monitoring vibration levels over time allows the plant engineer
to predict the problems before serious damage and avoid the shutdown of plant. When pending
problems are discovered early the plant engineer has the opportunity to schedule maintenance
and reduce down time in a cost effective manner. Vibration analysis is used as a tool to determine
machine condition and find specific location of machinery problems. This expedites repairs and
minimizes cost. In rolling element bearings, contamination of lubricant grease by solid particles
is one of the several reasons for an early bearing failure. In this respect, this project work deals
with the effect of contamination of lubricant by solid particles on the dynamic behavior of rolling
bearings. Generally different materials such as Silica, metal-burr, dolomite-powder, and iron-ore,
all at three concentration levels and different particle sizes were used to contaminate the
lubricant. Here silica is used as a contaminant. Experimental tests have been performed on the
ball bearings lubricated with grease, and the trends in the amount of vibration affected by the
contamination of the grease were determined. The contaminant concentration as well as the
particle size is varied for each test. Vibration signatures were analyzed with respect to root mean
square (RMS) values of amplitude in terms of acceleration and also with respect to acceleration
values at particular defect frequencies. From the results, some important conclusions are made
about the bearing performance. The results show significant variation in the overall RMS
acceleration value and also on acceleration value at every particular defect frequency on varying
the contaminant material, particle size of the contaminant, contaminant concentration and
running parameters like speed.
INTRODUCTION
Rolling element bearings are common components in rotating machinery. Bearings are in a
central position in the monitoring of the condition of rotating machinery. Measurement is usually
carried out at the points at which a shaft is supported with bearings and hence the vibration
generated by the bearing is included in the vibration signal whether the signal is analyzed or not.
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The goal in the development of vibration measurement methods for rolling bearings has usually
been to develop techniques for detection of bearing faults in their earliest stage.
METHODOLOGY
The silica sand material at three concentration levels and three different particle sizes are used to
contaminate the lubricant. Experimental tests have been performed on the ball bearings
lubricated with grease, and the trends in the amount of vibration affected by the contamination of
the grease are determined. The contaminant concentration as well as the particle size is varied.
Vibration signatures are analyzed in terms acceleration values at particular defect frequencies
and also in terms of overall root mean square (RMS) values. From the results, some fruitful
conclusions are made about the bearing performance. The results show significant variation in
the RMS acceleration values on varying the contaminant material, concentration and particle
size. At high frequencies, failure of a machine may result from excessive forces which break
down the lubrication allowing the surface of bearings to fail (due to metal-to-metal contact).
These excessive forces are directly proportional to acceleration (Force = mass x acceleration),
because of same here for analysis acceleration parameter is selected.
FUNDAMENTALS OF CONDITION MONITORING OF GREASE
CONTAMINATED BEARINGS
The deep groove ball bearings are used due to their high load carrying capacity and suitability for
high running speeds. The load carrying capacity of a ball bearing is related to the size and
number of the balls. Bearing is generally considered as the central part of every rotating
machine. The failure of same can cause the complete breakdown of machine. Following are the
few causes for bearing failure.
Figure 1. Distribution of the reasons for which rolling element bearings did not reach their
calculated lifetime.
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GREASE ACTS AT THE ROLLING CONTACT
Figure 2. Grease at rolling contact
Where,
Po=Hertzian pressure,
2b=Pressure surface axis according to Hertz,
1=Entry side,
2=Exit side,
3=Deformation of the roller,
4=Lubricant film,
5=deformation of the raceway,
6=Hertzian pressure distribution,
7= EHD Pressure distribution
The Guidelines for Selecting the Lubricant as follows,
When temperature < 100o
C, Grease is suitable.
When product of bore(mm)*speed(rpm) < 2,00,000, Grease is suitable.
[In this project work 30 mm*1495 rpm=44,850<2,00,000 therefore selecting the Grease as a
lubricant.]
Grease is suitable for low and moderate loads.
VIBRATION SIGNATURE MONITORING OF ROLLING BEARINGS :
Vibration analysis is a very powerful condition monitoring technique which is becoming more
popular and common practice in industry. As a general rule, machines don’t breakdown or fail
without some form of warning, which is indicated by an increased vibration level. The increasing
level in the vibration signature of a machine can provide a variety of information on many
components and structures such as gear meshing frequencies, bearings, structural resonances,
and even electrical faults. Different components and defects are generated at different
frequencies. Using signal processing techniques to analyze the time and frequency spectrums it
can be possible to determine the defect and natural frequencies of various structural components.
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The amplitude of the vibration signature gives an indication of the severity of the problem, whilst
the frequency can indicate the source of the defect. Most vibration analysis instruments today
utilize a Fast Fourier Transform (FFT) which is a special case of the generalized Discrete Fourier
Transform and converts the vibration signal from its time domain representation to its equivalent
frequency domain representation. However, frequency analysis (sometimes called Spectral
Analysis or Vibration Signature Analysis) is only one aspect of interpreting the information
contained in a vibration signal. Frequency analysis tends to be most useful on machines that
employ rolling element bearings and whose main failure modes tend to be the degradation of
those bearings, which typically exhibit an increase in characteristic frequencies associated with
the bearing geometries and constructions. In contrast, depending on the type of machine, its
typical malfunctions, the bearing types employed, rotational speeds, and other factors, the skilled
analyst will often need to utilize additional diagnostic tools, such as examining the time domain
signal, the phase relationship between vibration components and a timing mark on the machine
shaft historical trends of vibration levels, the shape of vibration, and numerous other aspects of
the signal along with other information from the process such as load, bearing temperatures, flow
rates, valve positions and pressures to provide an accurate diagnosis.
EXPERIMENTAL WORK
To obtain the desired output following experiment is carries out, wherein an experimental setup
is selected along with different bearing samples prepared by adding different contaminants.
PREPARATION OF SAMPLE
Sample term indicates the test bearing which will have the contaminant added in the lubricant.
The samples are prepared by following steps,
STEP 1) BEARING SELECTION:
In this project work SKF 6206 deep groove ball bearing is used. Geometry of bearing is shown in
fig. and geometrical specification are given in table no.1
Table 1. Specifications of SKF 6206 Ball Bearing
Parameter Value in
mm
Outside Diameter
(D)
62
Bore Diameter (D) 30
Bearing Width (B) 16
Ball Diameter
(BD)
9.6
Cage
Diameter(Dc)
46
Contact Angle (β) 00
Number of Balls
(n)
9
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STEP 2) CONTAMINANT SELECTION
Silica contaminant particles are used for deliberately contaminating the lubricant of the bearings.
The required contaminants of different size ranges were obtained using standard sieves and
alpine air classifier. The different contaminant levels were obtained using Electronic balance.
The separation of particles size and contaminant level preparation was carried out for the silica
particles for the selected particles size ranges and contaminant levels. Most of the researchers
are used, Metal-Burr, Dolomite Iron-Ore etc. The silica sand contaminant has the different
physical properties, i.e. hardness, brittleness and malleability.
Silica: This material is taken from foundry industry. According to information collected, many
times the particles of these materials are observed in Lubrication-Failed bearings. Hence this
material is selected for study.
Quantity Selection:
The above selected materials are sieved in sieves of different sizes, available in Metallurgy lab of
the foundry. The three different sizes are selected as, 53µm, 75 µm and 106 µm for each
material. The size is specified by considering the size of sieve used for sieving. The sizes are
mentioned below. The contaminant retained on 53µm is here considered as 53µm size for
convenience, and the same is applied for other two sizes.
Table 2.Sieve sizes used for contaminant material
Sr.No. On Sieve(µm) Below
Sieve(µm)
1 53 75
2 75 106
3 106 153
These sample sizes are added in the grease in different concentration levels as 5%(0.25gm),
15%(0.75gm) and25%(1.25gm) of the grease weight. The grease weight is selected by
considering a standard empirical relation. The relation is given as, G=0.005DB
=0.005*62*16
G=4.96 gm =5 gm(say)
Where G is grease quantity (gm), D is the bearing outside diameter (mm), and bearing width
(mm). [12]. Bye the calculation made above, the quantity estimated is 5gm.
TEST SAMPLE PREPARATION:
The above selected contaminants are added in the grease and the different mixtures are
prepared. The same mixture is added in the bearing, for this a new bearing is taken. The
grease which is already present in the bearing is removed by washing the bearing by
Kerosene or diesel. The prepared grease sample is then added in the bearing. These bearings
are given the specific names as S1C1,S1C2 S1C3 etc. Such 9 bearings are prepared by adding
the contaminated grease and one bearing is taken as standard bearing. In this way total 10
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sample bearings are prepared. For every type of contaminant and for every size and for every
concentration a new bearing is taken.
Table 3.Bearing sample numbers with specifications
Sr.
No.
Contaminant
Mtl.
Contaminant
Size
(µm)
Contam-inant
Concen.
(%)
Bearing
Sample
name
1 Healthy Nil Nil Healthy
2 Healthy Nil Nil Healthy
3 Healthy Nil Nil Healthy
4 Healthy Nil Nil Healthy
5 Silica Sand 53 5 S1C1
6 Silica Sand 53 15 S1C2
7 Silica Sand 53 25 S1C3
8 Silica Sand 75 5 S2C1
9 Silica Sand 75 15 S2C2
10 Silica Sand 75 25 S2C3
11 Silica Sand 106 5 S3C1
12 Silica Sand 106 15 S3C2
13 Silica Sand 106 25 S3C3
EXPERIMENTAL SETUP
The experiment is carried out on the setup which is prepared in the workshop of Dr. D. Y. Patil
School of Engineering, Lohegaon, Pune. The figure 6 shows the actual setup on which
experimental work is carried out. The specifications of the setup are provided below. The setup
is designed in order to have the negligible setup vibrations. Here the set-up vibrations term is
very important. When the shaft starts running at high speed the all components start vibrating
because of small mechanical errors in alignment. The setup vibrations mixup with bearing
vibrations and create the inaccuracy occurs in the measurement. The current setup has
negligible such structural vibrations. The setup consists of a motor, two bearings, contact type
tachometer, SKF FFT Analyzer, single channel accelerometer etc. The whole setup is mounted
on a 20 mm thick metal plate with four acrylic pads
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Figure 3. Actual Experimental setup
RUNNING PARAMETERS
Every sample bearing prepared is tested under constant running parameters. The two parameters
are size and weight percentage. There is constant speed is selected for carrying out the test. The
constant speed selected is 1495 RPM, Total nine combinations are obtained by varying size and
weight percentage, for carrying out the test on every single sample bearing. The details of
experiment for any sample bearing can be given as follows.
In this way total 9 tests are conducted on nine bearing samples and in this way total 9 bearing
samples are tested. Hence in the complete experimental work total 10 tests are conducted.
Table 4.Required Frequency Equations
Characteristic
frequency
(Hz)
symbol Equations
Shaft Rotational
Frequency Fs N/60
Inner race
defect frequency Fid n/2*fr[1+(bd/pd)*cosβ]
Outer race
defect frequency Fod n/2*fr[1-(bd/pd)*cosβ]
Ball defect
frequency Fbd Pd/2bd*Fr[1-
(bd/pd)2
*(cosβ)2
Contaminated Bearing
Digital
Tachomete
r
SKF single channel
FFT Analyser
Healthy BearingSpeed
Adjuster
Magnetic
Accelerometer
Single phase
Motor
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Where,
N:-rotational speed of shaft in RPM
n:-No. of balls,
Fr:-Shaft Rotation Frequency,
bd:-Ball Diameter,
β -Contact angle,
pd:-Pitch Diameter
ACTUAL TEST AND DATA COLLECTION
Every test followed a sequence of three steps. In the first step, the bearing is running in healthy
grease in order to stabilize the grease temperature. In the second step, the test is continued in
healthy grease to collect the vibration data at constant speed. In the third step, the contaminated
grease is applied to the bearing. A separate bearing is used for each concentration level of the
test. Vibration signals with contaminated grease are acquired from the bearing housing at
constant speeds. The above procedure is repeated for all concentration levels. Data is recorded
and analyzed with respect to peak values and the root mean square (RMS) values, related to
specific defect frequencies.
The calculated fault frequencies at constant speeds are given in above table. These values are
further used for analysis. The acceleration values are recorded at these frequency values.
Table 5.Calculated Fault frequencies at 1495 speed
Figure 4. Silica Sand Contaminants with healthy & Tested Bearings
Sr. (N) (Fs) (Fid) (Fod) (Fbd)
No
. RPM Hz Hz Hz Hz
1 1495 24.92 139.32 89.70 114.16
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RESULTS AND DISCUSSION
By running all the sample bearings at constant running condition, the vibration signatures are
obtained. All the collected signatures are analyzed for vibration amplitude in terms of
acceleration value. It is found that there is no much effect of load variation hence here for
discussion only readings obtained for setup load are presented.
ANALYSIS OF SILICA AS CONTAMINANT
As discussed in above chapter, the data is tried to analyze in terms of peak-values and RMS
values, related to specific defect frequencies. Following are some examples of vibration
signatures obtained from test by using FFT analyzer when silica is used as a contaminant. The
figures show the Acceleration Vs. Frequency graphs for the bearing sample no. S1C1 to S3C3
including Healthy bearing when running at a speed of 1495 RPM.
Figure 5. Acceleration-Frequency plot for bearing sample S3C1 running at 1495 RPM
Figure 6. Acceleration-Frequency plot for bearing sample S3C2 running at 1495 RPM
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Figure 7. Acceleration-Frequency plot for bearing sample S3C3 running at 1495 RPM
The Fig. no. 5, 6 and 7 are the signatures obtained for same contaminant material but with 106
µm size and the concentration level increased as 5%, 15%, 25% respectively. It shows that, as the
concentration level is increased, the acceleration value at all defect frequencies goes on
increasing as compare to 53 micron and 75 micron. This is happening because at higher particle
size at higher concentration levels the particles may not come in vicinity of rotating element.The
last three figures are obtained for same material with 106 µm size and concentration level varied
as, 5%, 15%, and 25% respectively. At this particle size as concentration level increased the
acceleration value at inner-race defect frequency decreases and at outer-race defect frequency
increases. This is happening because of more weight the particles tend to move the outer side of
bearing.
Figure 8. Acceleration-Frequency plot for Healthy bearing sample running at 1495 RPM
The Fig. no. 6 indicates the signatures obtained for healthy bearing with contaminant free grease.
It indicates all the frequencies are at minimum level this is happen because there is no medium
present in a grease which produce the vibrations in the same bearings.
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Figure 9. S3C1 @ 1495 RPM
Figure 10. S3C2 @ 1495 RPM
Figure 11. S3C3 @ 1495 RPM
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
S3C1 HEALTHY
Acceleration(m/s2)
S3C1 @ 1495 RPM
fs
fod
fbd
fid
0
0.01
0.02
0.03
0.04
0.05
0.06
S3C2 HEALTHY
Acceleration(m/s2)
S3C2 @ 1495 RPM
fs
fod
fbd
fid
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
S3C3 HEALTHY
Acceleration(m/s2)
S3C3 @ 1495 RPM
fs
fod
fbd
fid
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Figure 12. S3C3,s3c2,s3c1,healthy @ 1495 RPM
STATISTICAL APPROACH
Table 6. RMS & Creast Factor Values
Condition of Bearing RMS (m/s2
) Creast factor
Inner race defect
0.38 0.115
Outer race defect
0.77 0.075
Ball defect
0.72 0.095
According to statistical analysis defect detect ability[16] of overall power to be the best followed
by RMS and Crest factor measurement. At advance stage of material Wear, bearing damage
propagates as crest factor decreases with proportional to RMS value increases.
BEARING LIFE EQUATION APPROACH
Rated Life of Healthy Bearing
L10=(60*N*L10h)/106
…………………….(1)
L10=1435.2 million revolutions
L10=(C/P)n
………………………………..(2)
P=1728.74 N
P=XVFr+YFa……………………………(3)
P=fr=1728.74 N
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
S3C1 S3C2 S3C3 HEALTHY
fs
fod
fbd
fid
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According to ISO-281:2007 the modified or adjusted rating life Lnm of the bearing can be
calculated from,
Lnm=a1*a2*a3*aiso*L10……………………(4)
Where,
Lnm=modified or adjusted rating life in million revolutions for special material characteristics
and operating conditions.
Note (1) : This life is calculated if, in addition to the load and speed other influences are known
such as,
1) Special material characteristics.
2) Lubrication
3) A reliability 90%
a1-Life modification factor for a reliability
a2-Life adjustment factor for special material characteristics for standard rolling bearings steels.
Generally a2=1 for bearings steels.
a3-Life adjustment factor for special operating conditions in particular for the lubrication.
Note (2) : To calculate a3 first calculate viscosity ratio K=V/V1
Where K= Viscosity ratio
V=Kinematic viscosity of lubricant at operating temperature(40o
C) in mm2
/sec.
V1=Reference viscosity of lubricant at operating temperature(40o
C) in mm2
/sec.
Note (3) : the reference viscosity V1 is determined from the mean bearing diameter dm and the
operating speed in N.
Note (4) : alternatively the reference viscosity V1 can also be calculated using the following
standard formulas,
- V1= 45000*N-0.83
*dm-0.5
………………...(5)
for N<1000RPM
- V1= 4500*N-0.5
*dm-0.5
…………………..(6)
forN>1000 RPM
Now the Grease lubricant density is,0.91 g/cm3
at standard operating temperature(40o
C)
Calculation of V1:
Therefore by using above equations,reference viscosity V1 in mm2
/sec is,(1495 RPM> 1000
RPM)
- V1=4500*N-0.5
*dm-0.5
-------------------------forN>1000 RPM,(1495 RPM> 1000 RPM)
V1=4500*(1495)-0.5
*(46)-0.5
V1=4500*0.02586*0.1474
V1=17.15 mm2
/sec
Calculation of V:
At 40o
C and N=1495 RPM
V=50 mm2/sec
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Calculation of K:
K=V/V1=50/17.15
K=2.94 i.e contaminants are present in the lubricant is proved
Calculation of a3
a3=life adjustment factor for special operating conditions in particular for the lubrication.
at K=2.94, a3=3 million revolutions.
Now we have calculated values are:
a1= 1………………………...90% reliability consider
a2=1……………………standard rolling bearing steel
a3=3……………………………………..from K=2.94
L10=1435.2 million revolutions
Calculation of aiso- Life adjustment factor for contamination of the lubricant.
aiso= [{(ec*Cu)/p}*K]……………………………..(7)
ec=Contamination factor= 0.3
Cu=fatigue load limit= 514(N)
K=viscisity ratio= 2.94
P=equivalent dynamic load=1728.74N
Therefore,
aiso=[{(ec*Cu)/p}*K]
aiso= [{(0.3*514)/1728.74}*2.94]=0.2622
or as dm=46mm and dm<100 mm; ec=0.3 to 0.1
Therefore,
aiso=0.2622
Lnm=a1*a2*a3*aiso*L10……………………from Eq.(4)
Lnm=1*1*3*0.2622*1435.2
Therefore,
Lnm=1128.92 million revolutions.
BEARING FEM ANALYSIS:
Generally ball bearing is a circular component with inner race, outer race, balls and cage. The
shaft is fitted into the inner bore diameter of the bearing. The parts of the bearings are subjected
to different types of loads and stresses. Apart from this the bearing failure happens due to
different reasons namely introduction of contaminants in lubricants, misalignment, dirt,
corrosion, insufficient lubrication, overloading, misassemble etc. Therefore bearing should be
capable to sustain these distortions that are induced due to contaminants and other causes. In
present study to analyze the bearing the harmonic analysis has been used because as all the
components of ball bearings are rotated at constant 1495 speed. During analyzing the bearing
harmonically, the coefficient of friction between the contaminant and outer race or coefficient of
friction between balls and contaminant has been increase so that the stress level in the contact
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zone has increases and it is concluded that, the contaminants are affected on performance of ball
bearing by simply seeing the stress color contour.
PROBLEM DEFINITION FOR HARMONIC ANALYSIS:
The harmonic analysis of bearing by FEM ensures the following parameters satisfactory,
1) To ensure that bearing withstand the harmonic stresses induced due to solid contaminants
and bearing rotation. The harmonic stresses are those stresses which arise due to rotating
motion of the machine member.
2) To determine the effect of solid contaminants effect on outer race, inner race and balls of ball
bearing.
DATA FOR BEARING GEOMETRY DEFINITION:
The bearing is a complicated structure. The parameters required for FEM analysis are only
presented instead of giving all geometrical data. Few of the important specifications of selected
bearings are as follows,
Bearing outside diameter, (D) : 62 mm
Bearing bore diameter, (d) : 30 mm
Bearing width, (B) : 16 mm
Ball diameter, (BD) : 9.6 mm
Cage diameter (Dc) : 46 mm
Contact angle, (β) : 0
Number of balls, (n) : 9
The material properties which are important for the analysis, are listed as under,
Material : Bearing Steel
Young’s Modulus (E) : 2.1 x 105 MPa.
Poisson’s Ratio (µ) : 0.3
Density : 8000 kg/m3
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GEOMETRY CREATION:
The modeler of ANSYS is somewhat weak as compared to the modeling software’s like Catia,
solid works, creo etc. available for the purpose. Creo 2.0 is one of the competent alternatives.
The Creo 2.0 is used to model the bearing with all intricate geometric details. The solid model
created in Creo 2.0 is shown in fig.5.3
Figure 13.Solid model of the SKF 6206 Ball Bearing in Creo 2.0
The created solid model was brought into the ANSYS analysis environment using ANSYS –
Creo 2.0 interface. Solid model of the typical bearing is complex piece as it has no. of balls,
outer race, inner race, and cage. Bearing has many features like outer race, balls, inner race. In
ANSYS, solid model is divided into number of small elements. This process is called creating
subassemblies
ELEMENT SELECTION AND MESHING:
In simple terms meshing means discretization of entire body into finite number of elemental
volumes call elements and interconnected boundaries are called as nodes. An element is the
building block of the finite element model. SOLID 95 Element is used for the 3-D modeling of
ball bearing. It can tolerate irregular shapes without as much loss of accuracy. Solid95 has
compatible displacement shapes and are well suited to model curved boundaries. The element is
defined by 20 nodes having three degrees of freedom per node that is translation in nodal X, Y, Z
directions. The element may have any spatial orientation. SOLID95 has plasticity, creep, stress
stiffening, large deflection, and large strain capabilities.
Figure 14.Solid 95 Geometry
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Figure 15.Meshed model of the bearing
Figure 16.Total numbers of nodes & elements used for analysis
Meshing is an important step in FEA analysis. The meshing is adequately done to obtain the
accurate results while computation. When more the number of elements taken, better accuracy is
obtained but simultaneously, the computational time increases tremendously. Total 237983
elements are used in this analysis. In order to obtain accurate information about the stress
distribution, more elements are placed at the corners, rounds, and at the contacting points by
using ANSYS smart meshing capability. Smart meshing is the special feature in ANSYS meshing
capability, which places as much number of elements at points where stress gradient and strain
gradient are more. The ultimate purpose is to obtain more accurate information at the very
sensitive places.
BOUNDARY CONDITIONS - HARMONIC ANALYSIS
Structural loading simply means that fixing outer race and allow rotating inner race and balls.
The red color shows in fig. 5.5 is contact region between inner race and balls. The fixed support
shown in blue color is provided at outer race and the yellow color shows that the inner race with
rotation of shaft.
Figure 17 Contact Region Figure 18 Boundary Conditions
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HARMONIC RESPONSE ANALYSIS
Harmonic analyses are used to determine the steady-state response of a linear structure to loads
that vary sinusoidal (harmonically) with time, thus enabling you to verify whether or not your
designs will successfully overcome resonance, fatigue, and other harmful effects of forced
vibrations.
In a structural system, any sustained cyclic load will produce a sustained cyclic or harmonic
response. Harmonic analysis results are used to determine the steady-state response of a linear
structure to loads that vary sinusoidal (harmonically) with time, thus enabling you to verify
whether or not your designs will successfully overcome resonance, fatigue, and other harmful
effects of forced vibrations.
In the selected case study stress and vibration analysis of SKF 6206 ball bearing is discussed.
The schematic representation of effect of solid contaminants on outer race is shown in fig. 19 &
fig. 20
Figure 19 Von-Misses stresses on outer race and Balls for healthy bearing
Figure 20 Von-Misses stresses on outer cage and Balls for contaminated bearing
The FEA analysis outcome is the maximum stresses and amplitude plot induced on outer race
and ball bearing to show the effect of solid contaminants. The 3 major kinds of analysis normally
performed on bearing includes, statistical analysis, FEM analysis & rated life of bearing analysis.
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In the current study, all above 3 types of analysis are performed and their results shows that the
solid contaminants affects the performance of ball bearing.
MODE-SUPERPOSITION HARMONIC ANALYSIS:
The mode-superposition method sums factored
The mode-superposition method sums factored mode shapes (obtained from a modal analysis) to
calculate the harmonic response. It is the only method allowed in the ANSYS Professional
program. The procedure completes through following five main steps,
i) Building the model.
ii) Obtaining the modal solution.
iii) Obtaining the mode-superposition harmonic solution.
iv) Expanding the mode-superposition solution.
v) Reviewing the results.
vi)
EXPAND THE MODE-SUPERPOSITION SOLUTION:
The expansion pass starts with the harmonic solution in which calculation has been done of
displacement, stress, and force solution. These calculations are done only at frequencies and
phase angles that you specify. Therefore, before you begin the expansion pass, you should review
the results of the harmonic solution using POST26 and identify the critical frequencies and phase
angles. An expansion pass is not always required. For instance, if you are interested mainly in
displacements at specific points on the structure, then the displacement solution could satisfy
your requirements. However, if you want to determine the stress or force solution, then you must
perform an expansion pass.
MODALANALYSIS:
A modal analysis determines the vibration characteristics (natural frequencies and mode shapes)
of a structure or a machine component. It can also serve as a starting p point for another, more
detailed, dynamic analysis, such as a transient dynamic analysis, a harmonic analysis, or a
spectrum analysis. The natural frequencies and mode shapes are important parameters in the
design of a structure for dynamic loading conditions. You can also perform a modal analysis on a
pre-stressed structure, such as a spinning turbine blade or rotating bearings.
Figure 22 Rotational Velocity Figure 10.Frequencies at 150 RPM
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STEPS INVOLVED IN MODALANALYSIS:
To start the analysis, initially the screen details are required to be refreshed. The preliminary
housekeeping i.e. where to save the results and analysis files, name of the program etc. are
carried out.
CHANGE JOB NAME: FILE > CHANGE JOB NAME > I/P JOB NAME
Change Directory:
File > Change Directory
Import Geometry:
File > Import > Creo 2.0 > model name
The geometry created in Creo 2.0 is imported in ANSYS work bench through ANSYS-Creo2.0
interface through step file format. A solid model is created by taking the exact dimensions as per
specifications given by manufacturer catalogue.
Figure 21 Imported Models From Creo 2.0.
PREPROCESSOR:
Preprocessor > Select Preferences > Structural
The outer cage area surfaces are selected and constrained for all degrees of freedom.
PREPROCESSOR:
Preprocessor > Element type > Add/Edit > Elements
SOLID 95 Element is a higher order 3-D, 20 node element.
MATERIAL PROPERTIES:
Preprocessor > Material model > i/p Young’s modulus, Poisson’s ratio
Application of the fix boundary condition at outer race (all DOF Zero), boundary conditions are
applied by considering inner race rotates with balls. The model after boundary conditions may be
seen as shown in figure 24.
Figure 24 Structural boundary conditions of ball bearing
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1) Meshing:
Preprocessor > Mesh Tool > Fine Mesh
Solving the solution for reviving the effect: Now ball bearings areas are selected. The
corresponding nodes are automatically selected. The coefficient of friction value is applied
between selected nodes. The above sub assembly for given coefficient of friction is solved.
2) Solution:
Solution > New Solution > Nodal
To see the results and stress contours the final command issued in postprocessor.
3) Post Processor:
Post Processor > Solve > Current LS
4) Post Processor:
Post Processor > Results
Results and their Physical Interpretation:
After applying the boundary conditions, the problem was solved by the ANSYS solver. ANSYS
solver formulates the governing structural stress strain equation for each and every element and
these formulates governing equations is solved for the deformations from which all the other
quantities such stresses, strains etc. can be calculated. The stress pattern for the highest
contaminant size and highest concentration level i.e. S3C3 is observed by the use of post
processing tool. The various differentiating color contours of the stresses are shown at left side of
the figure 25. The figure.25 represents various contours of deformation in three dimensional
displacements.
Figure 25 Von-Misses Stresses on Outer Race & balls for Healthy Bearings
Figure 26 Von-Misses Stresses on Outer Race for Defective (S3C3) Bearings
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Graph 1 Convergence for Healthy Bearing
Graph 2 Convergence for Contaminated Bearing (S3C3)
Graph 3 Frequency response for Healthy Bearing in Z-Direction
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Graph 4 Frequency response for Contaminated Bearing in Z-Direction
RESULTS
1) Stress level in the contact zone between balls & contaminants is high in case of contaminated
bearing compared with healthy bearing
2) Rated life of healthy bearing=L10=1435.2million revolutions.
3) Rated life of contaminated bearing=Lnm=1128.92 million revolutions.
4) i.e. due to contaminants introduced in a Grease the rated life of bearings is reduced by 21.34
%=22% (Say)
5) From the overall discussion it is proved that there is a effect of solid contaminants on
vibrations and bearing life of ball bearings.
FUTURE SCOPE
It is found that following things can be added as extension to this work,
1. Application of the Finite element analysis method to verify the current results.
2. Other type of bearing can be tested by using the same method.
3. The displacement parameter of vibration can be applied for analysis.
4. The other condition monitoring methods like stator-current method can be applied.
Acknowledgments
I would like to thank Prof. A. P. Deshmukh, Prof. S. K. Rathode, Prof. Amol Patil, Prof. P. A.
Makasare Prof. Kashinath Munde, Prof.Ganesh Pokale, Mr. Ankur Kanchan, Dr. S. S. Sonavane
for giving me all his support & cooperation for my project work.
Nomenclature
Fs: Shaft rotational frequency
Fid- inner race defect frequency
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Fod- outer race defect frequency
Fbd- ball defect frequency
Fcd- cage rotational frequency
V=Kinematic viscosity
V1=Reference viscosity
K= Viscosity ratio
a1-Life modification factor for a reliability
a2-Life adjustment factor for special material characteristics
a3-Life adjustment factor for special operating conditions in particular for the lubrication.
L10-Rated life of healthy bearing
Lnm -Rated life of contaminated bearing
aiso- Life adjustment factor for contamination of the lubricant.
ec-Contamination factor
Cu-fatigue load limit
P-Equivalent dynamic load.
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