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Vibration and Control
Experimental investigations to establish correlation between Stribeck curve, specific film thickness and
statistical parameters of vibration and sound signals in a spur gear system
Sang-Kwon Lee and M Amarnath
Journal of Vibration and Control published online 4 August 2014
DOI: 10.1177/1077546314544164
The online version of this article can be found at:
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Article
Abstract
The use of a gear as a power transmitting machine element in engineering applications is quite extensive. Under service
conditions gear teeth contacts have a tendency for deterioration due to contact fatigue, wear, material defects, lubrication failure etc. Gear teeth surface deterioration triggers several types of failures such as abrasive wear, scuffing, micro
pitting and spalling. The abovementioned faults influence the changes in the vibration and sound signals in the gear
system. This paper presents the novel results of experimental investigations carried out to assess the surface fatigue
wear in a spur gear system. Estimation of specific film thickness, measurement of reduction in tooth thickness, visual
examination of wear mechanisms on the gear teeth and their effects on the statistical parameters of vibration and sound
signals are considered in this study. In order to confirm the hypothesis of dependency of surface fatigue wear, specific film
thickness and sound and vibration signals the results of statistical parameters obtained from sound and vibration signals
have been correlated with the Stribeck curve.
Keywords
Lubricant film thickness, sound, tooth thickness, vibration, wear
1. Introduction
Gear drives are one of the very common power transmission systems which appear in various kinds of rotating machinery and control systems. The service life of a
gear system depends upon a variety of factors viz. lubrication, design, contamination, environment etc.
Lubricating oils are used in a gear system to reduce
friction and wear by interposing a lm of material
between the gear teeth. If the lubricant lm at the
gear teeth contacting surfaces collapses, the heat and
wear on the gear teeth increases rapidly thereby causing
various wear mechanism such as micro pitting, abrasive
wear spalling, scoring etc. The presence of severe wear
on the gear teeth reduces stiness in the gear teeth contact and such an operating condition alters the vibration and sound signals of a gear system (Bartz, 1993;
Lee and White, 1998; Hohn and Michaelis, 2003;
Yesilyurt, 2003). In the last two decades several
researchers have published their research articles on
1
Acoustics and Vibration Signal Processing Laboratory, Inha University,
Republic of Korea
2
Machine Dynamics and Tribology Laboratory, Indian Institute of
Information Technology Design and Manufacturing, Jabalpur, India
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hmin
R
Figure 1. Gear teeth contacts in Stirbeck diagram as a function of specific film thickness .
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This parameter is designed to increase in the presence of heavy uniform wear on gear teeth surfaces. On
the other hand, spectrum analysis of sound and vibration signals can be used in conjunction with these statistical parameters to detect wear severity on the gear
tooth surfaces.
N
1X
xn x 4
h P
i2
N n1 1 N
2
n1 xn x
N
maxx
RMS
RMSd
RMSyd
4. Experiments
4.1. Experimental setup, sensors and equipments
Figure 2 shows the experimental setup used to conduct
fatigue test experiments on the spur gear pair. It consists of 0.75 kW direct current (DC) motor and a single
stage spur gearbox with a pair of gears mounted on two
parallel shafts, the driving pinion had 24 teeth and the
driven gear had 25 teeth. The pinion was considered for
fault assessment.Table 1 gives the detailed specications of the gearbox and test conditions. The DC
motor rotation was controlled by a variable speed controller which was used to drive the input shaft. The
eddy current magnetic brake was used to provide
torque load to the gearbox, this device has a maximum
torque capacity of 12 Nm.
The vibration and sound signals were acquired using
a Bruel & Kjaer 4506 triaxial accelerometer and Bruel
& Kjaer 4189 microphone respectively. The accelerometer was mounted on the input shaft bearing. A commercial data acquisition system LMS SCADASIII was
used to acquire the sound and vibration signals, these
signals were sampled at 8.2 kHz, acquired simultaneously and stored in a personal computer for post processing. Each time domain signal consisting of the
average of 16 time history plots, which seemed to be
sucient to reduce the noise in vibration and sound
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Pinion
Number of teeth
24
Deport angle
0.00
Pressure angle
20
Height
6.53
Module
3
Face width
30
Pitch diameter
72.72
Diameter of base
68.34
Diameter of head
78.78
Pinion speed
450 rpm
Nonimal load
44 N
Torque on pinion shaft
012 Nm
Material properties of gears
SM45C
Brinell hardness number hardness (HRB) 167
Poissons ratio
0.3
Youngs modulus
2 105 N/mm2
Gear
25
0.00
20
6.53
3
30
75.75
71.18
81.81
signals. Vibration signals in the Z - direction were considered to assess the wear propagation on gear teeth.
The microphone was used to acquire sound signals
from the gearbox which was installed in an acoustically
rigid anechoic chamber. The microphone was kept at a
distance of 5.5 cm to 6 cm in the vicinity of input shaft.
This position was considered after many trials (near
eld condition): this procedure was successfully used
in our previous work (Amarnath and Praveen
Krishna, 2012). The walls, ceiling and oors were
glued with 8 inch acoustic wedges. The photograph of
the experimental setup with data acquisition system
and sensors is shown in Figure 3.
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scung damage was observed on the gear tooth surfaces. The EHL regime provides a protecting layer
between the gear tooth surfaces. The EHL lm formation is decreased at high temperature and lower viscosities resulted in scung wear propagation on gear tooth
surfaces An increase in the wear has an eect on the
roughness of the gear teeth anks (Hohn and
Michaelis, 2004; Rak Sari et al., 2007; Hohn et al.,
2009) . A gradual increase in the gear tooth surface
roughness values, the EHL and boundary lubrication
regimes are observed during 400 h and 600 h of operation as shown in Figure 7(c). Due to the prolonged
operating time, surface wear propagates thereby causing the transition of the lubrication regime i.e. the gear
system enters into a boundary lubrication regime after
800 hours of operation as shown in Figure 7(e). Wear
mechanisms and their corresponding eects on vibration and sound signals of the gear system are discussed
in the next sections.
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Figure 7. Specific film thickness versus time at 12 Nm gearbox input torque (a) 0200 hours (b) 400 hours (c) 600 hours (d) 800
hours (e) 1000 hours.
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Figure 8. Surface fatigue wear on the pinion teeth surfaces obtained at 12 Nm gearbox input torque.
Operating
time
Measured tooth
flank thickness (mm)
(three teeth
separated by 120 )
Average
tooth
thickness
(mm)
Reduction
in
thickness
(%)
0 hours
200 hours
400 hours
600 hours
800 hours
1000 hours
5.62
5.51
5.44
5.34
5.21
5.18
5.58
5.47
5.45
5.41
5.32
5.22
0
1.9
2.3
3.04
4.65
6.41
5.59
5.48
5.49
5.51
5.25
5.22
5.55
5.42
5.43
5.38
5.53
5.28
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have been discussed in the authors previous publications (Amarnath and Praveen Krishna 2012, 2013) and
interested readers can refer to these research articles.
The vibration spectrum encompasses abundant information related to the wear propagation on gear teeth
and the corresponding eects on dynamical characteristics of the gear meshing process.
Spectrum analysis of vibration and sound signals
can be used to locate and obtain the severity of fault
growth on the gear teeth (Yesilyurt 1997; Yesilyurt
et al., 2003; Serrato et al., 2007; Amarnath et al.,
2012; Amarnath and Praveen Krishna, 2013). In the
present experiment, the pinion speed was set to
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Figure 17. Fast Fourier transform spectra of vibration signals at 12 Nm gearbox input torque (a) 0 h (b) 250 h (c) 500 h (d) 750 h
(e) 1000 h.
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Figure 18. Fast Fourier transform spectra of sound signals at 12 Nm gearbox input torque (a) 0 h (b) 250 h (c) 500 h (d) 750 h
(e) 1000 h.
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Nomenclature
o
u
E0
absolute viscosity
pressure viscosity coefficient
peripheral velocity
combined
Youngs
modulus
1 E2
E0 E 12E
2 E 1 2
2
E1 , E2
1, 2
d0,1 , d0,2
w
F
FU
db
M
b
l
R
Ra
d0,1
d0,2
diameters of gear and pinion respectively
mesh angle
normal tooth force per unit width F =b
FU
normal tooth force F cos
2M
peripheral force db
pitch circle diameter
torque
tooth width
specific film thickness
combined surface roughness
arithmetic average of surface roughness
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