Tribological failure analysis of gear contacts of Exciter Sieve gear boxes

In the present paper the premature failure of gear contact encountered in Exciter Sieve gear boxes has been analyzed. The cause of gear contact failure is identified by simulating the load bearing capacity of lubricants and conducting controlled experiments on an Amsler disk-on-disk tribo tester. The results of performance behavior (i.e., load carrying capacity of lubricants, contact friction and weight loss of test specimens) of the simulated gear contacts have been reported. The theoretical and experimental results indicate presence of mixed to partial elastohydrodynamic lubrication conditions in the gear contact. To mitigate the problem of scuffing and scoring in the gear contacts, lubricating oils with extreme pressure additives and Base oil without additive have been tested and performance results are reported.     

Dynamic response and acoustic radiation of double-leaf metallic panel partition under sound excitation

The transmission of sound through a rectangular double-leaf metallic panel partition clamp mounted on a rigid acoustic baffle has been investigated analytically. It is found that, at a specific frequency, sound transmission through the structure is significantly enhanced for incident sound with a certain incidence angle. This physical phenomenon, namely, transparent effect, is analyzed in terms of both dynamical panel modal responses and radiating acoustic pressure. The enhanced transmission is attributed to the unique mass-air-mass effect of the double-panel partition system. Numerical results clearly demonstrate that this effect does not completely stem from the point-to-point out-of-plane motion of the two panels, due to the additional constraining effect of the clamped supports.     

Design systems for gear elements made of cotton fiber-reinforced plastics

We look on the cotton fiber reinforced plastics as industrial gear materials, and have been developing design systems for industrial gears made of cotton fiber-reinforced plastics. In this report, we deal with a method estimating for tooth root stresses caused by bending movements under running conditions. The gear material used was cotton fiber plain woven cloth reinforced phenolic resin laminates. Paper-reinforced phenolic resin laminates, a commonly used material, was used as a control for comparison. The main dimensions of the gears were module 3–5 mm and tooth width 25 mm. First, accelerations of gears were measured under running conditions to estimate dynamic performance. Second, fracture tests of gear teeth were carried out under bending loads. Different fracture modes at tooth roots for cotton fiber-reinforced plastics and phenolic resin gears were observed. The fractures occurred at a high position from the tooth root in the case of the cotton fiber-reinforced plastics gear because the cotton fiber-reinforced plastics had excellent cleavage and shear strength. This gear also had higher strength for tooth bending loads. Third, the mechanical properties of the gears were researched by tensile, bending, and shearing tests. It was clear that the cotton fiber-reinforced plastics had excellent properties in cleavage fracture between laminates and shear strength. Finally, we proposed a design method for this gear, which considers the cleavage and shear strength.     

噪声异常压缩机的声诊断分析

通过声品质评价方法分析了噪声异常转子压缩机试验样机,并计算出A声级、响度、粗糙度和尖锐度作为声品质的客观评价指标,结果表明与正常压缩机相比,该噪声异常压缩机具有较差的声品质。声阵列技术能够精确定位复杂形状的目标声源,与传统采用声级计测试相比,能够获得更加丰富的声场信息。为了诊断出压缩机的异常噪声,通过声阵列技术在全频段对该异常压缩机进行了声源识别定位分析,找到了影响压缩机噪声的关键频率点及相应的噪声源,从而为压缩机噪声的改善提供了有力证据。     

基于心理声学与声强法的汽车怠速异常噪声源识别

针对一样车开发阶段怠速工况出现的怠速车内异常噪声(简称异响),基于心理声学的分析方法对此异响进行声品质的客观量评价,定量地反映了正常噪声与异常噪声的主观感受差别;运用频谱分析技术初步确定怠速异响噪声的主要频谱范围在200~400 Hz;对异常噪声在200~400 Hz进行衰减滤波并进行声学回放与听觉比较,进一步验证了怠速异响的频率范围;采用声强测试得出发动机舱内声场分布,快速准确地确定了发动机正时轮系是引起怠速异响的主要来源,通过控制发动机悬置动刚度能够有效消除怠速异响。     

声强法在柴油机表面辐射噪声源识别中的应用

根据声强测试原理，应用B＆K 3560C便携式振动与噪声测试系统中的声强测试模块，对4190型柴油机的表面辐射噪声源进行识别。绘制了三维声强图，找出了该发动机的各个辐射面上的主要噪声源，并对其进行了排序，分析了这些噪声源的产生根源。提出了控制主要噪声源的一些建议，以便于进一步降低该柴油机的噪声水平。     

汽车噪声源识别实验研究

声强测试分析方法是一种有效的噪声源识别和声场分析方法。依据声强法的原理,对某型汽车的车外辐射噪声进行声强测试,并在此基础上对该车的主要噪声源进行识别和研究,为降低该型汽车的表面辐射噪声提供有效的参考依据。     

室内声学测量中数字化声源性能的分析

文章选取了三种典型的数字化声源信号：膺噪声、线性调频声及调幅脉冲波包进行分析，阐明了它们的共同优点及各自的特点。其中膺噪声的应用较为普遍，而线性调频声则由于其原理简单，在实际测量中具有更大的优越性。提出了在混响时间足够长的房间内作测量时，可以不考虑扬声器本身的响应对测量结果所产生的影响。     

基于小波-倒频谱的齿轮故障诊断方法及应用

利用振动信号采集到的齿轮故障信息,依据点蚀的故障机理和频谱特征,采用小波分解将信号分解在不同频带,有效抑制了背景噪声,从而得到故障特征频带,获得周期性突变的故障信息。选择故障所处频带重构信号,对故障进行诊断。结合倒频谱方法可以有效地识别故障特征频率。结果表明小波分析与倒频谱相结合是齿轮故障检测中一种有效的诊断方法。     

机油泵齿轮异响检测方法

针对小型内燃机机油泵齿轮异响,对右盖异响声信号进行频谱分析和包络分析,识别异响频率,然后通过声学互动滤波技术对不易区分的异响频率进行再次识别,结果显示:机油泵异响频率并没有体现在齿轮啮合频率上,而是存在于多个高频段,随着转速的增加,异响频率不变,能量逐渐增大.然后运用声强法结合内燃机顶面和右侧面声强分布图,对内燃机声信...     

Special manufacturing and characteristics of basalt fiber reinforced hybrid polypropylene composites: Mechanical properties and acoustic emission study

Basalt fiber reinforced, polypropylene matrix hybrid composites were manufactured in the process of carding, needle-punching and pressing. Hemp, glass and carbon fibers were applied besides basalt fiber in these composites. In order to achieve a sufficient interfacial adhesion, the fibers were treated with the reaction mixture of maleic acid anhydride and sunflower oil. The hybrid effect in these composites was examined as a function of fiber content and fiber combination. The strength properties of hybrid composites improved owing to surface treatment and this was proven by mechanical tests and microscopic analysis, as well. Acoustic emission methods revealed that there is a correlation between the physical parameters of sound waves that occurred during failure and the mechanical properties.     

Failure Analysis of a Diesel Engine Gear System Consisting of Camshaft and Crankshaft Gears

A failure investigation was conducted on a diesel engine gear system consisting of a driven camshaft and drive crankshaft gears that were used in a truck. The gears are made from a nitrided 42CrMo steel. Adjacent teeth fracture and plastic deformation regions appeared on the gears after a 400 h run test of the gear system. Fractography indicates that fatigue fracture is the dominant failure mechanism for the gear teeth. Although the appearance of needle-like nitrides in the nitrided layer and the narrow depth of the compound layer may decrease the fatigue strength of the camshaft gear, these do not suffice to lead to the premature fracture of the gear teeth. Geometrical analysis of the gears was performed and compared with an analysis of unfailed gears that had experienced a run test for 1800 h. The comparison reveals that the small fillet radius at the root area of the camshaft gear concentrated the stresses and is mainly responsible for fatigue fracture of the teeth. The camshaft gear is the component that initiated trouble in the gear system. The appearance of severe plastic deformation on the gear faces is caused by the fractured teeth crushing the teeth faces and being embedded in the grooves between teeth.     

Failure Analysis of Cracked Gear Shafts

Two gear shafts cracked during the fabrication. The cracks are through the grooves associated with the gear teeth and propagated completely across the shaft. Fractography on the cracked teeth indicates that the crack origins are about 3.5 to 4.0 mm from the groove and exhibit pointlike features. Fracture surfaces near the crack origin regions were intergranular, and the fracture appeared to have occurred instantaneously. Metallurgical analysis indicates that decarburization had occurred on the surfaces of the gear shafts, but occurrence of decarburization has no relation to the cracking. Cracking occurred during the carburization-quenching process and originated at a cluster of Al₂O₂ complex inclusions. The thermal stress produced by quenching drove the cracking process.     

Diagnostic of fatigue damage severity on reinforced concrete beam using acoustic emission technique

Fatigue damage assessment using non-destructive testing on structures as well as reinforced concrete (RC) beam has become an attention for recent decades. In this paper, diagnostic of fatigue damage in RC beams using acoustic emission (AE) technique was investigated. Based on severity analysis of AE signal strength during service life of the beams, bath–tub curves derived from AE signal are presented and divided into three stages; burn-in, steady state and burn-out. At the same time, deflection in the RC beams also has been analyzed.     

Non-contact measurement of acoustic emission in materials by laser interferometry

The non-contact measuring system of acoustic emission (AE) by laser interferometry was developed to detect AE signals and analyze microfracture quantitatively during materials testing. The capability of this system was estimated by comparison between simulated AE signals due to glass capillary breaking and calculations using the finite element method. The systemcould measure AE signals during practical tensile tests of carbon fiber reinforced plastics. This technique was also applied to the thermal cycle test of ceramic/metal coatings, and AE signals during cooling were successfully detected and analyzed by a deconvolution method to evaluate quantitatively the microfracture process.     

Identification of Fiber Breakage in Fiber Reinforced Plastic by Low-Amplitude Filtering of Acoustic Emission Data

A new low-amplitude filtering technique has been developed for the identification of fiber breakage in fiber reinforced plastics from acoustic emission data. In this approach, the acoustic emission hits associated with fiber breakage are separated from the hits associated with other failure mechanisms by filtering out the low amplitude hits from the measured data. The lowest remaining amplitude upon the cumulative plot of the remaining hits vs. load coinciding with the cumulative signal strength vs. load plot is taken as the borderline between fiber breakage hits and non-fiber breakage hits. Experiments were conducted on unidirectional-fiber specimens and complex-fiber specimens to examine the efficacy of the proposed technique. Evaluation of the experimental results by visual inspection and extensive scanning electron microscope studies verifies the low-amplitude filtering technique as a reliable tool for identifying fiber breakage in fiber reinforced plastics.     

Wavelet transform of acoustic emission signals in failure of model composites

The fundamental characteristics of acoustic emission (AE) signals, such as the attenuation, and frequency dependency of AE signals, were investigated and the fracture process of the single fiber composite (s.f.c.) was examined. As a result, the frequencies of AE signals were almost unchanged, while the amplitudes attenuated greatly with the increment of the propagation length. This proved that the frequency analysis is an effective way in processing AE signals of composite materials. In the fracture process of the s.f.c., the number of AE events was in a good agreement with the number of fiber breakages, and the sources of AE signals were the failure modes at fiber breakages. Using the proposed time-frequency method of wavelet transform (WT) to process AE signals, the microfailure modes at a fiber breakage and the microfracture mechanism, such as the sequence of each failure mode and their interaction, were made clearer. These indicated that both processing methods of AE signals, fast-Fourier transform and WT, were powerful for identifying the microfailure modes and for elucidating the microfracture mechanisms in composite materials.     

瞬态声品质时域传递路径方法与应用研究

全球化竞争日趋激烈和消费者对汽车舒适性要求越来越高,迫使各汽车公司加快了NVH开发进程,汽车声音的控制逐渐进入声品质控制阶段。创新性提出一种基于时域传递路径分析的瞬态声品质分析方法和流程。采用考虑奇异值截断的去卷积滤波器方法建立时域去卷积网络。构建了车内瞬态噪声合成模型,并在时频域上分解和分析了发动机的结构声贡献和空气声贡献。通过视听比较合成噪声和测量噪声,以评审团主观评价打分的形式来验证模型的准确性。进一步对合成噪声进行主观声品质评价,将车内噪声合成模型延伸至虚拟车内声品质预测模型。基于该模型,找到声品质贡献较大的路径,并且通过虚拟修改各路径传递函数值,来优化车内声品质,为制定车内声品质改善措施提供指导依据。     

Identification of microbiologically influenced corrosion (MIC) in industrial equipment failures

The present study demonstrates different approaches towards MIC identification in three real cases of technological equipment failures.

In the first case the failure of carbon steel heat exchanger as a result of tubes, lids, tube sheets, and connection pipes clogging was investigated. Chemical analysis of cooling water and precipitates, as well laboratory screening of deposits for bacteria, revealed that activity of iron-oxidizing bacteria present in cooling water led to heat exchanger blockage.

The second case is related to MIC detection on floating roofs made of magnesium–aluminum alloy following a 3-weeks hydro-test. Corrosion tests carried out on the original and sterilized water used in hydro-test confirmed MIC process.

In the third case the potential of MIC occurrence in engine cooling system made of cast aluminum alloy and filled with 20% ethylene glycol coolant solution was evaluated. The simulation tests allowed determining the real causes of the severe corrosion attack of examined system, including MIC high probability.     

冲击载荷下的齿轮动应力变化规律数值分析

基于虚拟制造方法建立了滚剃工艺的精确圆柱直齿轮三维几何模型,并进行线外啮合冲击动态仿真分析,得到了可靠的齿轮动应力变化规律。仿真结果表明：冲击加载时,不同工况下齿根两侧最大动应力的出现位置呈对称分布;冲击载荷下,齿根最大应力大于ISO标准静强度理论值,最大应力位置比ISO标准确定的最危险截面位置偏高;冲击载荷峰值相同时,冲击时间越短,产生的动应力越大。