Dr. M. Amaranth Assistant Professor, Mechanical Engineering IIITD&M Jabalpur Jabalpur (MP)
Dr. M. Amaranth Assistant Professor, Mechanical Engineering IIITD&M Jabalpur Jabalpur (MP)
Dr. M. Amaranth Assistant Professor, Mechanical Engineering IIITD&M Jabalpur Jabalpur (MP)
Dr. M. Amaranth
Assistant Professor, Mechanical Engineering
IIITD&M Jabalpur
Jabalpur (MP)
Overview of presentation
Introduction
Lubricant film thickness
Experimental setup with sensors and
instruments
lubrication regimes and wear severity
Wear particle analysis
Oil degradation analysis
Summary and conclusions
Study
cost of
fuels,
spares
etc.,
Plant in detoriation
condition
Installation of
CM
Routine operation of
CM system
Cash fow
Cash fow
Increase in
consumption
of spare etc.,
Plant in good
condition
Time/usage
Time/ Usage
Assessment of vibration,
acoustics, oil/wear particle
parameters ???
Fault detection in early stage
Minimize machinery down time
Evaluate the performance of machine
elements
Improvements in design of machine
elements
INTRODUCTION
Gears
and
bearings
are
the
most
common
detection
in
geared
systems:
vibration
M. Amarnath, et al.
Experimental investigations on the effects of
analysis,
oil/wear
particle
analysisfilmand
acoustic
reduction
in Gear
tooth stiffness
and lubrication
thickness
in a spur
geared system, Tribology International,42, 340-352, 2009
signal analysis.
LUBRICANT FILM
THICKNESS
Effective lubrication is critically important because it prevents
direct tooth contact
Reduces friction, prevents high vibration levels, removes heat
generated in meshing and protects the gear from corrosion
Drastic fall in lubricant film thickness is responsible for gear
failure modes, viz., micro pitting, macro pitting, gear staining,
scuffing and mild wear
Alternative methods to predict gear failure is often related to film
thickness and specific film thickness, which are an indication of
contact severity
Prof. D. Dowson ,
University
independently
driven
by
Fig. fourballweartester
EXPERIMENTAL SETUP
Data Acquisition
system
B &K amplifier
Accelerometer
Test gear
box
Thermo
couple
Rigid coupling
Torque adjustment
coupling
Torque shaft
Fig. Experimental
Experimental investigations
on the effects of reduction in Gear tooth
setup
th, et al.
12
film thickness in a spur geared system, Tribology International,42, 340-352, 2
EXPERIMENTAL SETUP
Fig. Experimental
setup
B&K charge
amplifier
Thermo couple
B&K Accelerometer
Test gear box
Slave gear
box
marnath, et al. Experimental investigations on the effects of reduction in Gear tooth stiffne
14
cation film thickness in a spur geared system, Tribology International,42,
340-352, 2009
EXPERIMENTAL SETUP
Data Acquisition
system
B &K amplifier
Accelerometer
Test gear
box
Thermo
couple
Rigid coupling
Torque adjustment
coupling
Torque shaft
Fig. Experimental
setup
Experimental investigations on the effects of reduction in Gear tooth stiffne
marnath, et al.
15
cation film thickness in a spur geared system, Tribology International,42, 340-352, 2009
0.13
min
w
h
(2)
min
R
o
is the absolute viscosity in centi Poise,
is modulus of elasticity
is peripheral velocity
RESULTS
85
75
Tem peratureC
70
65
60
55
0 Nm
59 Nm
118 Nm
177 Nm
236 Nm
295 Nm
360 Nm
413 Nm
80
50
45
40
35
30
25
0
9
8
0 Nm
59 Nm
118 Nm
177 Nm
236 Nm
295 Nm
354 Nm
413 Nm
7
6
5
4
3
2
1
Time (Hours)
3
4
Time (Hours)
3.5
3.0
360 Nm
413 Nm
2.5
2.0
1.5
1.0
18
36
54
72
90
108
126
144
162
180
198
216
Time (Hours)
(ASM
rnath, et al. Experimental investigations on the effects of reduction in Gear tooth stiffnes
tion film thickness in a spur geared system, Tribology International,42, 340-352, 2009
20
Applications
IC engines oil samples
collected from crank case
Gear box
Ball/ roller bearing
Pin on disc machine
4 ball testing machine etc
M. Amarnath, C. Sujatha and S. Swarnamani, Detection and Diagnosis of Gear Tooth Wear
Through Metallurgical and Oil Analysis, Tribology Online a journal published by the Japanese
Society of Tribologists., 5 (2), 102, 2010
M. Amarnath, C. Sujatha and S. Swarnamani, Detection and Diagnosis of Gear Tooth Wear
Through Metallurgical and Oil Analysis, Tribology Online a journal published
by the Japanese
29
Society of Tribologists., 5 (2), 102, 2010
Fe concentration
Atomic
absorption
spectroscopy(AAS)
A procedure for the quantitative
determination of chemical elements.
Fe
CONCENTRATION
F e C o n c e n tr a tio n ( P P M )
350
300
250
200
150
100
50
0
20
40
60
80
100
Time (Hours)
Initial Damage
Occurs
elements
(gears
and
bearings)
can
be
monitoring
of
critical
components.
EXPERIMENTAL SETUP
M. Amarnath and
S.K. Lee Experimental investigations to establish correlation
between Stribeck curve, specific film thickness and statistical parameters of vibration and
sound signals in a spur gear system Journal of Vibration Control. - (Accepted Journal
Impact factor : 4.2).
Anechoic chamber
Power supply
D.C load
controlle
r
D.C Speed
controller
Eddy
current
brake
D.C motor
Microphon
e
Acceleromet
er
Test gear
Data Acquisition
M. Amarnath and
S.K. Lee Experimental investigations to establish correlation
between Stribeck curve, specific film thickness and statistical parameters of vibration and
sound signals in a spur gear system Journal of Vibration Control.41- (Accepted Journal
Impact factor : 4.2).
M. Amarnath and
S.K. Lee Experimental investigations to establish correlation
between Stribeck curve, specific film thickness and statistical parameters of vibration and
sound signals in a spur gear system Journal of Vibration Control.42- (Accepted Journal
Impact factor : 4.2).
Fig.
M. Amarnath and
S.K. Lee Experimental investigations to establish correlation
between Stribeck curve, specific film thickness and statistical parameters of vibration and
sound signals in a spur gear system Journal of Vibration Control.43- (Accepted Journal
Impact factor : 4.2).
Fig. Specific film thickness versus time at 12 Nm gearbox input torque (a) 0- 200 hours (b) 400 hours (c)
600 hours (d) 800 hours (e) 1000 hours
M. Amarnath and S.K. Lee Experimental investigations to establish correlation between Stribeck curve, specific film
44 Journal of Vibration Control. thickness and statistical parameters of vibration and sound signals in a spur gear system
(Accepted Journal Impact factor : 4.2).
Fig.
M. Amarnath and
S.K. Lee Experimental investigations to establish correlation
between Stribeck curve, specific film thickness and statistical parameters of vibration and
sound signals in a spur gear system Journal of Vibration Control.45- (Accepted Journal
Impact factor : 4.2).
Fig. Surface fatigue wear on the pinion teeth surfaces obtained at 12 Nm gearbox input torque
M. Amarnath and
S.K. Lee Experimental investigations to establish correlation
between Stribeck curve, specific film thickness and statistical parameters of vibration and
sound signals in a spur gear system Journal of Vibration Control. - (Accepted Journal
Impact factor : 4.2).
M. Amarnath and
S.K. Lee Experimental investigations to establish correlation
between Stribeck curve, specific film thickness and statistical parameters of vibration and
sound signals in a spur gear system Journal of Vibration Control. - (Accepted Journal
Fig.
Accelerometer
(a)
(c)
(b)
(d)
(e)
Fig. Applications of
accelerometer [ 1-5]
Accelerometer
location
[ 4]
Fig. Accelerometer mounting methods
Noise measurement
Sound pressure or acoustic pressure
is the local pressure deviation from the
ambient
(average,
or
equilibrium)
atmospheric pressure, caused by a sound
wave.
Sound pressure level (SPL) or sound
level is a logarithmic measure of the
effective sound pressure of a sound
relative to a reference value.
TYPICAL PLOTS
40
50
40
30
30
20
20
10
m/s2
m /s
10
-10
-20
-20
-30
-30
-40
0
0
-10
-40
500
1000
1500
2000
Time (0.25 S)
-50
0
500
1000
1500
2000
Time (0.25 S)
M. Amarnath, Praveen Krishna, Empirical Mode Decomposition of Acoustic Signals for Diagnosis
of Faults in Gears and Rolling Element Bearings, IET Science, Measurement & Technology,
6 (4), 279-287, 2012. . (Citations: 10) ( Journal Impact factor: 1.00).
Kurtosis
n 1
1
N
N
n 1
x ( n) x
RMS yd
Conventional
methods
x t
1
jt
X e
d
A m p litu d e m /s
10
6
4
2
0
2000
4000
6000
8000
10000
Frequency (Hz)
A m p litu d e m /s
10
6
4
2
0
2000
4000
6000
8000
10000
Frequency (Hz)
M. Amarnath and
S.K. Lee Experimental investigations to establish correlation
between Stribeck curve, specific film thickness and statistical parameters of vibration and
sound signals in a spur gear system Journal of Vibration Control. - (Accepted Journal
Impact factor : 4.2).
Fig.
Crest factor of sound signals
versus
at 12 Nm gearbox input torque
M. Amarnath and
S.K. Lee Experimental investigations to establish correlation
between Stribeck curve, specific film thickness and statistical parameters of vibration and
sound signals in a spur gear system Journal of Vibration Control. - (Accepted Journal
Impact factor : 4.2).
Fig.
ratio of vibration signals versus
. Energy ratio of sound signals versus
Energy
at
at 12 Nm gearbox torque
Nm gearbox input torque
M. Amarnath and
S.K. Lee Experimental investigations to establish correlation
between Stribeck curve, specific film thickness and statistical parameters of vibration and
sound signals in a spur gear system Journal of Vibration Control. - (Accepted Journal
Impact factor : 4.2).
18
Vibration Signals
Sound Signals
Kurtosis values
15
12
9
6
3
0
200
400
600
800
1000
Time (Hours)
M. Amarnath and
S.K. Lee Experimental investigations to establish correlation
between Stribeck curve, specific film thickness and statistical parameters of vibration and
sound signals in a spur gear system Journal of Vibration Control. - (Accepted Journal
Impact factor : 4.2).
Fig. FFT Spectra of sound signals (a) 0 h (b) 250 h (c) 500 h (d) 750 h (e)
1000 h
M. Amarnath and S.K. Lee Assessment of surface contact fatigue failure in a spur geared
system based on the vibration and tribological parameter analysis Measurement, 76, 32 44,
1.0
0.025
2
0.75
Amplitude (m/s )
0.000
0.5
1 fm
0.25
0.00
0
200
600
800
1000
0.000
0.5
0.00
0
1200
3 fm
2 fm
1 fm
0.25
200
400
4 fm
600
800
1000
1200
1000
1200
Frequency (Hz)
1.0
0.8
2
400
4 fm
Frequency (Hz)
1.0
Amplitude (m/s)
3 fm
2 fm
0.025
0.75
Amplitude (m/s )
Amplitude (m/s )
1.0
0.6
2 fm
3 fm
0.4
4 fm
1 fm
0.2
0.0
200
400
600
800
1000
1200
0.8
0.6
4 fm
2 fm
0.4
1 fm
0.2
0.0
Frequency
1.0 (Hz)
3 fm
200
400
600
800
Frequency (Hz)
Amplitude (m/s )
0.8
0.6
3 fm
2 fm
1 fm
0.4
4 fm
0.2
0.0
200
400
600
800
1000
1200
Frequency (Hz)
M. Amarnath and S.K. Lee Assessment of surface contact fatigue failure in a spur geared
66
system based on the vibration and tribological parameter analysis Measurement, 76, 32 44,
Gear
R - rolling
R
S
S - Sliding
S
R
S
R
S
Pinion
T1
T
2
R
O
Q
P
T1
Fig. Combination of sliding and rolling in gear teeth and worthy contacting points on gear and
pinion teeth
M. Amarnath and S.K. Lee Assessment of surface contact fatigue failure in a spur geared
system based on the vibration and tribological parameter analysis Measurement, 76, 32 44,
M. Amarnath and S.K. Lee Assessment of surface contact fatigue failure in a spur geared
system based on the vibration and tribological parameter analysis Measurement, 76, 32 44,