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.

Wear particle analysis and the evolution of the plastically deformed layer on Australian rail steel

Particle analysis methodology is presented, together with the morphology of the wear debris formed during rolling contact fatigue. Wear particles are characterised by their surface topography and in terms of wear mechanism. Rail-wheel materials are subjected to severe plastic deformation as the contact loading progresses, which contributes to a mechanism of major damage in head-hardened rail steel. Most of the current methodologies involve sectioning of the rail-wheel discs to trace material damage phenomena such as crack propagation and plastic strain accumulation. This paper proposes methodology to analyse the development of the plastically deformed layer by sectioning wear particles using the focussed ion beam (FIB) milling method. Moreover, it highlights the processes of oxidation and rail surface delamination during unlubricated rolling contact fatigue.

A mechatronic system applied to wear particle analysis

This paper describes the development of a mechatronic system for a predictive maintenance grounded on wear particle analysis. The reckoning of wear particles containing in lubricating industrial oils brings the image acquisition system into being. The ISO 4406:1999 standard is a guide to establish the counting and evaluation processes of particles. The system applied to the acquisition and analysis of the data consists of a digital camera, a monocular microscope and an oil filtering system. A computational program was developed with the application of Visual Microsoft C++ in a way to detain the oil sample image from the microscope slide to the computer screen. Quantitative analyses of the wear debris particles bulk are exploited applying a graphical interface that was developed to render the image processing of the sample test. The implemented system has a reachable cost thus it can be applied for schooling goals and for bolstering laboratories of minor industries and medium size companies.

Dynamical Evolution of Wear Particles in Nanocontacts

Nanoscale surface modification, by the interaction of sliding surfaces and mobile nanoparticles, is a critical parameter for controlling friction, wear and failure of surface structures. Here we demonstrate how nanoparticles form and interact in real-time at moving nanocontacts, with reciprocating wear tests imaged in situ at the nanoscale over > 300 cycles in a transmission electron microscope. Between sliding surfaces, friction-formed nanoparticles are observed with rolling, sliding and spinning motions, dependant on localised contact conditions and particle geometry. Over periods of many scratch cycles, nanoparticles dynamically agglomerate into elongated clusters, and dissociate into smaller particulates. We also show that the onset of rolling motion of these particles accompanies a reduction in measured friction. Introduction of nanoparticles with optimum shape and property can thus be used to control friction and wear in microdevices.

Physico-chemical characterization and oxidative reactivity evaluation of aged brake wear particles

Brake wear dust is a significant component of traffic emissions and has been linked to adverse health effects. Previous research found a strong oxidative stress response in cells exposed to freshly generated brake wear dust. We characterized aged dust collected from passenger vehicles, using microscopy and elemental analyses. Reactive oxygen species (ROS) generation was measured with acellular and cellular assays using 2′7-dichlorodihydrofluorescein dye. Microscopy analyses revealed samples to be heterogeneous particle mixtures with few nanoparticles detected. Several metals, primarily iron and copper, were identified. High oxygen concentrations suggested that the elements were oxidized. ROS were detected in the cell-free fluorescent test, while exposed cells were not dramatically activated by the concentrations used. The fact that aged brake wear samples have lower oxidative stress potential than fresh ones may relate to the highly oxidized or aged state of these particles, as well as their larger size and smaller reactive surface area.

Wear Particle Classifier System Based on an Artificial Neural Network

This paper describes a method of identifying morphological attributes that classify wear particles in relation to the wear process from which they originate and permit the automatic identification without human expertise. The method is based on the use of Multi Layer Perceptron (MLP) for analysis of specific types of microscopic wear particles. The classification of the wear particles was performed according to their morphological attributes of size and aspect ratio, among others. (C) 2010 Journal of Mechanical Engineering. All rights reserved.

Toxic effects of brake wear particles on epithelial lung cells in vitro

ABSTRACT: BACKGROUND: Fine particulate matter originating from traffic correlates with increased morbidity and mortality. An important source of traffic particles is brake wear of cars which contributes up to 20% of the total traffic emissions. The aim of this study was to evaluate potential toxicological effects of human epithelial lung cells exposed to freshly generated brake wear particles. RESULTS: An exposure box was mounted around a car's braking system. Lung cells cultured at the air-liquid interface were then exposed to particles emitted from two typical braking behaviours ("full stop" and "normal deceleration"). The particle size distribution as well as the brake emission components like metals and carbons was measured on-line, and the particles deposited on grids for transmission electron microscopy were counted. The tight junction arrangement was observed by laser scanning microscopy. Cellular responses were assessed by measurement of lactate dehydrogenase (cytotoxicity), by investigating the production of reactive oxidative species and the release of the pro-inflammatory mediator interleukin-8. The tight junction protein occludin density decreased significantly (p < 0.05) with increasing concentrations of metals on the particles (iron, copper and manganese, which were all strongly correlated with each other). Occludin was also negatively correlated with the intensity of reactive oxidative species. The concentrations of interleukin-8 were significantly correlated with increasing organic carbon concentrations. No correlation was observed between occludin and interleukin-8, nor between reactive oxidative species and interleukin-8. CONCLUSION: These findings suggest that the metals on brake wear particles damage tight junctions with a mechanism involving oxidative stress. Brake wear particles also increase pro-inflammatory responses. However, this might be due to another mechanism than via oxidative stress.

Wear particles and surface topographies are modulators of osteoclastogenesis in vitro

Prosthetic and osteosynthetic implants from metal alloys will be indispensable in orthopedic surgery, as long as tissue engineering and biodegradable bone substitutes do not lead to products that will be applied in clinical routine for the repair of bone, cartilage, and joint defects. Therefore, the elucidation of the interactions between the periprosthetic tissues and the implant remains of clinical relevance and several factors are known to affect the longevity of implants. Within this study, the effects of metal particles and surface topography on the recruitment of osteoclasts was investigated in vitro in a coculture of osteoblasts and bone marrow cells. The cells were grown in the presence of particles of different sizes and chemical composition or on metal discs with polished or sandblasted surfaces, respectively. At the end of the culture, newly formed osteoclasts were counted. Osteoclastogenesis was reduced when particles were added directly to the coculture. The effect depended on the size of the particles, small particles exerting stronger effects than larger ones. The chemical composition of the particles, however, did not affect the development of osteoclasts. In cocultures grown on sandblasted surfaces, osteoclasts developed at higher rates than they did in cultures on polished surfaces. The data demonstrate that wear particles and implant surfaces affect osteoclastogenesis and thus may be involved in the induction of local bone resorption and the formation of osteolytic lesions, leading eventually to the loosening of orthopedic implants.

Tooth wear: diet analysis and advice

Diet analysis and advice for patients with tooth wear is potentially the most logical intervention to arrest attrition, erosion and abrasion. It is saliva that protects the teeth against corrosion by the acids which soften enamel and make it susceptible to wear. Thus the lifestyles and diet of patients at risk need to be analysed for sources of acid and reasons for lost salivary protection. Medical conditions which put patients at risk of tooth wear are principally: asthma, bulimia nervosa, caffeine addiction, diabetes mellitus, exercise dehydration, functional depression, gastroesophageal reflux in alcoholism, hypertension and syndromes with salivary hypofunction. The sources of acid are various, but loss of salivary protection is the common theme. In healthy young Australians, soft drinks are the main source of acid, and exercise dehydration the main reason for loss of salivary protection. In the medically compromised, diet acids and gastroesophageal reflux are the sources, but medications are the main reasons for lost salivary protection. Diet advice for patients with tooth wear must: promote a healthy lifestyle and diet strategy that conserves the teeth by natural means of salivary stimulation; and address the specific needs of the patients' oral and medical conditions. Individualised, patient-empowering erosion WATCH strategies; on Water, Acid, Taste, Calcium and Health, are urgently required to combat the emerging epidemic of tooth wear currently being experienced in westernised societies.

Road Dust from Pavement Wear and Traction Sanding

Vehicles affect the concentrations of ambient airborne particles through exhaust emissions, but particles are also formed in the mechanical processes in the tire-road interface, brakes, and engine. Particles deposited on or in the vicinity of the road may be re-entrained, or resuspended, into air through vehicle-induced turbulence and shearing stress of the tires. A commonly used term for these particles is road dust . The processes affecting road dust emissions are complex and currently not well known. Road dust has been acknowledged as a dominant source of PM10 especially during spring in the sub-arctic urban areas, e.g. in Scandinavia, Finland, North America and Japan. The high proportion of road dust in sub-arctic regions of the world has been linked to the snowy winter conditions that make it necessary to use traction control methods. Traction control methods include dispersion of traction sand, melting of ice with brine solutions, and equipping the tires with either metal studs (studded winter tires), snow chains, or special tire design (friction tires). Several of these methods enhance the formation of mineral particles from pavement wear and/or from traction sand that accumulate in the road environment during winter. When snow and ice melt and surfaces dry out, traffic-induced turbulence makes some of the particles airborne. A general aim of this study was to study processes and factors underlying and affecting the formation and emissions of road dust from paved road surfaces. Special emphasis was placed on studying particle formation and sources during tire road interaction, especially when different applications of traction control, namely traction sanding and/or winter tires were in use. Respirable particles with aerodynamic diameter below 10 micrometers (PM10) have been the main concern, but other size ranges and particle size distributions were also studied. The following specific research questions were addressed: i) How do traction sanding and physical properties of the traction sand aggregate affect formation of road dust? ii) How do studded tires affect the formation of road dust when compared with friction tires? iii) What are the composition and sources of airborne road dust in a road simulator and during a springtime road dust episode in Finland? iv) What is the size distribution of abrasion particles from tire-road interaction? The studies were conducted both in a road simulator and in field conditions. The test results from the road simulator showed that traction sanding increased road dust emissions, and that the effect became more dominant with increasing sand load. A high percentage of fine-grained anti-skid aggregate of overall grading increased the PM10 concentrations. Anti-skid aggregate with poor resistance to fragmentation resulted in higher PM levels compared with the other aggregates, and the effect became more significant with higher aggregate loads. Glaciofluvial aggregates tended to cause higher particle concentrations than crushed rocks with good fragmentation resistance. Comparison of tire types showed that studded tires result in higher formation of PM emissions compared with friction tires. The same trend between the tires was present in the tests with and without anti-skid aggregate. This finding applies to test conditions of the road simulator with negligible resuspension. Source and composition analysis showed that the particles in the road simulator were mainly minerals and originated from both traction sand and pavement aggregates. A clear contribution of particles from anti-skid aggregate to ambient PM and dust deposition was also observed in urban conditions. The road simulator results showed that the interaction between tires, anti-skid aggregate and road surface is important in dust production and the relative contributions of these sources depend on their properties. Traction sand grains are fragmented into smaller particles under the tires, but they also wear the pavement aggregate. Therefore particles from both aggregates are observed. The mass size distribution of traction sand and pavement wear particles was mainly coarse, but fine and submicron particles were also present.

Analysis of polymerization time on abrasive wear of dental resins

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Comparisons of the two-body abrasive wear behaviour of four different ferrous microstructures with similar hardness levels

The abrasive wear resistance of four distinct metallurgical steel microstructures - bainite, pearlite, martensite and tempered martensite, with similar hardness levels was investigated. A pin-on-disc tribometer was used to simulate the two-body abrasive condition (i.e. the metallic surface abrading against the silicon carbide abrasive particles) and evaluate the specific wear rate of the microstructures. Each microstructure had a unique response towards the abrasion behaviour and this was largely evident in the friction curve. However, the multi-phase microstructures (i.e. bainite and pearlite) demonstrated better abrasion resistance than the single-phase microstructures (i.e. martensite and tempered martensite). Abrasion induced microstructural changes at the deformed surfaces were studied using sub-surface and topographical techniques. The properties of these layers (i.e. surface profile measurements) determined the amount of material loss for each microstructure. These were directly linked to the single-wear track analysis that highlighted a marked difference in their mode of material removal. Ploughing and wedge formation modes were dominant in the case of bainite and pearlite microstructures, whereas the cutting mode could be attributed to the higher material loss in the single-phase microstructures. The combination of brittle and ductile phases in the multi-phase microstructure matrix could be one of the driving factors for their superior abrasion resistance.

基于粗糙集-BP神经网络的发动机故障诊断

由于发动机光谱分析监控数据中磨损微粒种类过多,如果将这些微粒信息直接作为神经网络的输入,则存在输入层神经元过多、网络结构复杂等诸多问题。本文将粗糙集引入到发动机故障诊断中来,利用粗糙集在属性约简方面的优势,删除冗余磨损微粒,提取出重要磨损微粒,并将其作为BP神经网络的输入,建立发动机故障诊断模型。该方法降低输入层的神经元个数,简化了网络结构,缩短网络训练时间,并且由于剔除了冗余磨损微粒,减少了由该部分微粒信息不准确而带来的误差,有效提高了故障诊断的精确度。最后通过算例分析验证了相关算法和诊断模型的准确性和有效性。