Significance of aspect ratio of wear debris in condition monitoring

2020 ◽  
Author(s):  
Rakesh Ranjan ◽  
Subrata Kumar Ghosh ◽  
Manoj Kumar
Keyword(s):  
Aspect Ratio ◽  
Condition Monitoring ◽  
Wear Debris

Online condition monitoring of misaligned meshing gears using wear debris and oil quality sensors

2018 ◽  
Vol 70 (4) ◽  
pp. 645-655 ◽  
Author(s):  
Paras Kumar ◽  
Harish Hirani ◽  
Atul Kumar Agrawal
Keyword(s):  
Condition Monitoring ◽  
Wear Debris ◽  
Oil Quality ◽  
Spur Gear ◽  
Metallic Particle ◽  
Sem Images ◽  
Content Type ◽  
Moisture Sensor ◽  
Laser Alignment ◽  
Online Sensors

Purpose This paper aims to investigate the effect of misalignment on wear of spur gears and on oil degradation using online sensors. Design/methodology/approach The misalignment effect on gears is created through a self-alignment bearing, and is measured using laser alignment system. Several online sensors such as Fe-concentration sensor, moisture sensor, oil condition sensor, oil temperature sensor and metallic particle sensor are installed in the gear test rig to monitor lubricant quality and wear debris in real time to assess gearbox failure. Findings Offset and angular misalignments are detected in both vertical and horizontal planes. The failure of misaligned gear is observed at both the ends and on both the surfaces of the gear teeth. Larger-size ferrous and non-ferrous particles are traced by metallic particle sensor due to gear and seal wear caused by misalignment. Scanning electron microscope (SEM) images examine chuck, spherical and flat platelet particles, and confirm the presence of fatigue (pitting) and adhesion (scuffing) wear mechanism. Energy-dispersive X-ray spectroscopy analysis of SEM particles traces carbon (C) and iron (Fe) elements due to gear failure. Originality/value Gear misalignment is one of the major causes of gearbox failure and the lubricant analysis is as important as wear debris analysis. A reliable online gearbox condition monitoring system is developed by integrating wear and oil analyses for misaligned spur gear pair in contact.

Modelling of wear debris in planetary gear drive

2019 ◽  
Vol 71 (2) ◽  
pp. 199-204
Author(s):  
Rakesh Ranjan ◽  
Subrata Kumar Ghosh ◽  
Manoj Kumar
Keyword(s):  
Probability Distribution ◽  
Aspect Ratio ◽  
Wear Debris ◽  
Planetary Gear ◽  
Wear Particle ◽  
Distribution Model ◽  
Wear Particles ◽  
Slab Caster ◽  
Content Type ◽  
Exponential Probability

Purpose The probability distribution of major length and aspect ratio (major length/minor length) of wear debris collected from gear oil used in planetary gear drive were analysed and modelled. The paper aims to find an appropriate probability distribution model to forecast the kind of wear particles at different running hour of the machine. Design/methodology/approach Used gear oil of the planetary gear box of a slab caster was drained out and charged with a fresh oil of grade (EP-460). Six chronological oil samples were collected at different time interval between 480 and 1,992 h of machine running. The oil samples were filtered to separate wear particles, and microscopic study of wear debris was carried out at 100X magnification. Statistical modelling of wear debris distribution was done using Weibull and exponential probability distribution model. A comparison was studied among actual, Weibull and exponential probability distribution of major length and aspect ratio of wear particles. Findings Distribution of major length of wear particle was found to be closer to the exponential probability density function, whereas Weibull probability density function fitted better to distribution of aspect ratio of wear particle. Originality/value The potential of the developed model can be used to analyse the distribution of major length and aspect ratio of wear debris present in planetary gear box of slab caster machine.

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