Maintenance of a reducer by vibration and wear particles analysis

Purpose - The purpose of the paper is to provide information on wear debris on oil and vibration analysis as predictive maintenance techniques in reducer. Design/methodology/approach - The estate of a reducer is verified by analyzing the vibration and oil conditions of a test rig under well-designed conditions utilizing some predictive variables. Findings - According to the vibration and oil analysis it is found out what it was happening into the reducer without disassembling it. Practical implications - This paper demonstrates the use of oil debris analysis and vibration analysis as a technique that enhances preventive maintenance practices. The paper helps practitioners to utilize these techniques more effectively. Originality/value - This paper gives information about two predictive maintenance techniques with a test rig. © Emerald Group Publishing Limited.

Vibration and wear particles analysis in a test stand

Purpose - This paper aims to provide information on wear debris on oil and vibration analysis as predictive maintenance techniques. Design/methodology/ approach - The estate of a reducer is verified by analyzing the vibration and oil conditions of a test rig under some variables. Findings - According to the vibration and oil analysis it was found what was happening in the reducer without disassembling it. Originality/value - This paper gives information about two predictive maintenance techniques with a test rig. © Emerald Group Publishing Limited.

Vibration and oil analysis for monitoring problems related to water contamination in rolling

Trying to reduce particle contamination in lubrication systems, industries of the whole world spend millions of dollars each year on the improvement of filtration technology. In this context, by controlling fluid cleanliness, some companies are able to reduce failures rates up to 85 percent. However, in some industries and environments, water is a contaminant more frequently encountered than solid particles, and it is often seen as the primary cause of component failure. Only one percent of water in oil is enough to reduce life expectancy of a journal bearing by 80 percent. For rolling bearing elements, the situation is worse because water destroys the oil film and, under the extreme temperatures and pressures generated in the load zone of a rolling bearing element, free and emulsified water can result in instantaneous flash-vaporization giving origin to erosive wear. This work studies the effect of water as lubricant contaminant in ball bearings, which simulates a situation that could actually occur in real systems. In a designed bench test, three basic lubricants of different viscosities were contaminated with different contents of water. The results regarding oil and vibration analysis are presented for different bearing speeds.

Evaluation of modal analysis techniques using physical models to detect osseointegration of implants in transfemoral amputees

Non-invasive vibration analysis has been used extensively to monitor the progression of dental implant healing and stabilization. It is now being considered as a method to monitor femoral implants in transfemoral amputees. This paper evaluates two modal analysis excitation methods and investigates their capabilities in detecting changes at the interface between the implant and the bone that occur during osseointegration. Excitation of bone-implant physical models with the electromagnetic shaker provided higher coherence values and a greater number of modes over the same frequency range when compared to the impact hammer. Differences were detected in the natural frequencies and fundamental mode shape of the model when the fit of the implant was altered in the bone. The ability to detect changes in the model dynamic properties demonstrates the potential of modal analysis in this application and warrants further investigation.

Analysis of conical-cylinder shells fundamental characteristics for structural health diagnostics

This paper describes the formulation for the free vibration of joined conical-cylindrical shells with uniform thickness using the transfer of influence coefficient for identification of structural characteristics. These characteristics are importance for structural health monitoring to develop model. This method was developed based on successive transmission of dynamic influence coefficients, which were defined as the relationships between the displacement and the force vectors at arbitrary nodal circles of the system. The two edges of the shell having arbitrary boundary conditions are supported by several elastic springs with meridional/axial, circumferential, radial and rotational stiffness, respectively. The governing equations of vibration of a conical shell, including a cylindrical shell, are written as a coupled set of first order differential equations by using the transfer matrix of the shell. Once the transfer matrix of a single component has been determined, the entire structure matrix is obtained by the product of each component matrix and the joining matrix. The natural frequencies and the modes of vibration were calculated numerically for joined conical-cylindrical shells. The validity of the present method is demonstrated through simple numerical examples, and through comparison with the results of previous researchers.

Ability of modal analysis to detect osseointegration of implants in transfemoral amputees : a physical model study

Owing to the successful use of non-invasive vibration analysis to monitor the progression of dental implant healing and stabilization, it is now being considered as a method to monitor femoral implants in transfemoral amputees. This study uses composite femur-implant physical models to investigate the ability of modal analysis to detect changes at the interface between the implant and bone simulating those that occur during osseointegration. Using electromagnetic shaker excitation, differences were detected in the resonant frequencies and mode shapes of the model when the implant fit in the bone was altered to simulate the two interface cases considered: firm and loose fixation. The study showed that it is beneficial to examine higher resonant frequencies and their mode shapes (rather than the fundamental frequency only) when assessing fixation. The influence of the model boundary conditions on the modal parameters was also demonstrated. Further work is required to more accurately model the mechanical changes occurring at the bone-implant interface in vivo, as well as further refinement of the model boundary conditions to appropriately represent the in vivo conditions. Nevertheless, the ability to detect changes in the model dynamic properties demonstrates the potential of modal analysis in this application and warrants further investigation.

Some studies on free vibration of composite laminates

Free vibration analysis is carried out to study the vibration characteristics of composite laminates using the modified shear deformation, layered, composite plate theory and employing the Rayleigh-Ritz energy approach. The analysis is presented in a unified form so as to incorporate all different combinations of laminate boundary conditions and with full coverage with regard to the various design parameters of a laminated plate. A parametric study is made using a beam characteristic function as the admissible function for the numerical calculations. The numerical results presented here are for an example case of fully clamped boundary conditions and are compared with previously published results. The effect of parameters, such as the aspect ratio of plates, ply-angle, number of layers and also the thickness ratios of plies in laminates on the frequencies of the laminate, is systematically studied. It is found that for anti-symmetric angle-ply or cross-ply laminates unique numerical values of the thickness ratios exist which improve the vibration characteristics of such laminates. Numerical values of the non-dimensional frequencies and nodal patterns, using the thickness ratio distribution of the plies, are then obtained for clamped laminates, fabricated out of various commonly used composite materials, and are presented in the form of the design curves.

Finite element analysis of rotors

A finite element formulation for the natural vibration analysis of tapered and pretwisted rotors has been presented. Numerical results for natural frequencies for various values of the geometric parameters and rotational speeds, have been computed for the case of rotors with and without pretwist. A Galerkin solution for the fundamental has also been worked out and has been used to provide a comparison for the finite element results. Charts for rapid estimation of the fundamental frequency parameter of tapered rotors, have been included.

Analysis of continuum using boundary compatibility conditions of integrated force method

Static and vibration problems of an indeterminate continuum are traditionally analyzed by the stiffness method. The force method is more or less non-existent for such problems. This situation is primarily due to the incomplete state of development of the compatibility conditions which are essential for the analysis of indeterminate structures by the flexibility method. The understanding of the Compatibility Conditions (CC) has been substantially augmented. Based on the understanding of CC, a novel formulation termed the Integrated Force Method (IFM) has been established. In this paper IFM has been extended for the static and vibration analyses of a continuum. The IFM analysis is illustrated taking three examples: 1. (1) rectangular plate in flexure 2. (2) analysis of a cantilevered dam 3. (3) free vibration analysis of a beam. From the examples solved it is observed that the force response of an indeterminate continuum with mixed boundary conditions can be generated by IFM without any reference to displacements in the field or on the boundary. Displacements if required can be calculated by back substitution.

Capturing higher modes of vibration of micromachined resonators

MEMS resonators have potential applications in the areas of RF-MEMS, clock oscillators, ultrasound transducers, etc. The important characteristics of a resonator are its resonant frequency and Q-factor (a measure of damping). Usually large damping in macro structures makes it difficult to excite and measure their higher modes. In contrast, MEMS resonators seem amenable to excitation in higher modes. In this paper, 28 modes of vibration of an electrothermal actuator are experimentally captured–perhaps the highest number of modes experimentally captured so far. We verify these modes with FEM simulations and report that all the measured frequencies are within 5% of theoretically predicted values.

An experimental and numerical study of piezoceramic actuator hysteresis in helicopter active vibration control

An aeroelastic analysis is used to investigate the rate dependent hysteresis in piezoceramic actuators and its effect on helicopter vibration control with trailing edge flaps. Hysteresis in piezoceramic materials can cause considerable complications in the use of smart actuators as prime movers in applications such as helicopter active vibration control. Dynamic hysteresis of the piezoelectric stack actuator is investigated for a range of frequencies (5 Hz (1/rev) to 30 Hz (6/rev)) which are of practical importance for helicopter vibration analysis. Bench top tests are conducted on a commercially available piezoelectric stack actuator. Frequency dependent hysteretic behavior is studied experimentally for helicopter operational frequencies. Material hysteresis in the smart actuator is mathematically modeled using the theory of conic sections. Numerical simulations are also performed at an advance ratio of 0.3 for vibration control analysis using a trailing edge flap with an idealized linear and a hysteretic actuator. The results indicate that dynamic hysteresis has a notable effect on the hub vibration levels. It is found that the theory of conic sections offers a straight forward approach for including hysteresis into aeroelastic analysis.

Vibration of an Adhered Microbeam Under a Periodically Shaking Electrical Force

The vibration analysis of an adhered S-shaped microbeam under alternating sinusoidal voltage is presented. The shaking force is the electrical force due to the sinusoidal voltage. During vibration, both the microbeam deflection and the adhesion length keep changing. The microbeam deflection and adhesion length are numerically determined by the iteration method. As the adhesion length keeps changing, the domain of the equation of motion for the microbeam (unadhered part) changes correspondingly, which results in changes of the structure natural frequencies. For this reason, the system can never reach a steady state. The transient behaviors of the microbeam under different shaking frequencies are compared. We deliberately choose the initial conditions to compare our dynamic results with the existing static theory. The paper also analyzes the changing behavior of adhesion length during vibration and an asymmetric pattern of adhesion length change is revealed, which may be used to guide the dynamic de-adhering process. The abnormal behavior of the adhered microbeam vibrating at almost the same frequency under two quite different shaking frequencies is also shown. The Galerkin method is used to discretize the equation of motion and its convergence study is also presented. The model is only applicable in the case that the peel number is equal to 1. Some other model limitations are also discussed.

SteelConverter and Caltech VirtualShaker: Rapid Nonlinear Cloud-Based Structural Model Conversion and Analysis

STEEL, the Caltech created nonlinear large displacement analysis software, is currently used by a large number of researchers at Caltech. However, due to its complexity, lack of visualization tools (such as pre- and post-processing capabilities) rapid creation and analysis of models using this software was difficult. SteelConverter was created as a means to facilitate model creation through the use of the industry standard finite element solver ETABS. This software allows users to create models in ETABS and intelligently convert model information such as geometry, loading, releases, fixity, etc., into a format that STEEL understands. Models that would take several days to create and verify now take several hours or less. The productivity of the researcher as well as the level of confidence in the model being analyzed is greatly increased.

It has always been a major goal of Caltech to spread the knowledge created here to other universities. However, due to the complexity of STEEL it was difficult for researchers or engineers from other universities to conduct analyses. While SteelConverter did help researchers at Caltech improve their research, sending SteelConverter and its documentation to other universities was less than ideal. Issues of version control, individual computer requirements, and the difficulty of releasing updates made a more centralized solution preferred. This is where the idea for Caltech VirtualShaker was born. Through the creation of a centralized website where users could log in, submit, analyze, and process models in the cloud, all of the major concerns associated with the utilization of SteelConverter were eliminated. Caltech VirtualShaker allows users to create profiles where defaults associated with their most commonly run models are saved, and allows them to submit multiple jobs to an online virtual server to be analyzed and post-processed. The creation of this website not only allowed for more rapid distribution of this tool, but also created a means for engineers and researchers with no access to powerful computer clusters to run computationally intensive analyses without the excessive cost of building and maintaining a computer cluster.

In order to increase confidence in the use of STEEL as an analysis system, as well as verify the conversion tools, a series of comparisons were done between STEEL and ETABS. Six models of increasing complexity, ranging from a cantilever column to a twenty-story moment frame, were analyzed to determine the ability of STEEL to accurately calculate basic model properties such as elastic stiffness and damping through a free vibration analysis as well as more complex structural properties such as overall structural capacity through a pushover analysis. These analyses showed a very strong agreement between the two softwares on every aspect of each analysis. However, these analyses also showed the ability of the STEEL analysis algorithm to converge at significantly larger drifts than ETABS when using the more computationally expensive and structurally realistic fiber hinges. Following the ETABS analysis, it was decided to repeat the comparisons in a software more capable of conducting highly nonlinear analysis, called Perform. These analyses again showed a very strong agreement between the two softwares in every aspect of each analysis through instability. However, due to some limitations in Perform, free vibration analyses for the three story one bay chevron brace frame, two bay chevron brace frame, and twenty story moment frame could not be conducted. With the current trend towards ultimate capacity analysis, the ability to use fiber based models allows engineers to gain a better understanding of a building’s behavior under these extreme load scenarios.

Following this, a final study was done on Hall’s U20 structure [1] where the structure was analyzed in all three softwares and their results compared. The pushover curves from each software were compared and the differences caused by variations in software implementation explained. From this, conclusions can be drawn on the effectiveness of each analysis tool when attempting to analyze structures through the point of geometric instability. The analyses show that while ETABS was capable of accurately determining the elastic stiffness of the model, following the onset of inelastic behavior the analysis tool failed to converge. However, for the small number of time steps the ETABS analysis was converging, its results exactly matched those of STEEL, leading to the conclusion that ETABS is not an appropriate analysis package for analyzing a structure through the point of collapse when using fiber elements throughout the model. The analyses also showed that while Perform was capable of calculating the response of the structure accurately, restrictions in the material model resulted in a pushover curve that did not match that of STEEL exactly, particularly post collapse. However, such problems could be alleviated by choosing a more simplistic material model.