Rolling element bearings absolute life prediction using modal analysis

In this paper, the authors introduce an experimental procedure for predicting the fatigue life of each individual rolling element bearing separately using vibration modal analysis. The experimental procedure was developed based on a statistical analysis. A statistical analysis was performed to find an empirical model that correlates the dynamic load capacity of rolling bearings to their dynamic characteristics (Natural frequencies and damping). These dynamic characteristics are obtained from the frequency response function of each individual bearing that results from vibration modal analysis. A modified formula to the already known Lundberg-Palmgren life formula is proposed for rolling element bearings. Given the modified formula, one can predict the fatigue life of each individual rolling element bearing based on its dynamic characteristics. The paper compares the results from the modified formula with those from Lundberg-Palmgren formula. The modified formula provides an accurate prediction for the fatigue life of each individual bearing based on its dynamic characteristics. The experimental validation of the modified formula is considered for future work. Therefore, it can be used in various applications of rolling element bearings in machinery systems.     

Accurate measurement of residual stresses of 2219-T87 aluminum alloy friction stir welding joints based on properties of joints

In order to avoid the deviation caused by calculating the residual stresses of welding joints with the release coefficients of the same parent metal, a new method has been proposed based on the properties of weld joints. Since the mechanical property of 2195-F Al alloy is close to that of 2219-T87 Al alloy Friction stir welding (FSW) joint, 2195-F Al alloy is selected as the substitute material of 2219-T87 Al alloy FSW joint in the calibration test. Release coefficients of 2195-F Al alloy and proper correction coefficient are used to calculate the residual stresses of 2219-T87 Al alloy FSW joints. Compared to the results calculated with release coefficients of its parent metal, it has been proved that the proposed correction method is more precise in residual stresses measurement of weld joints. The mathematical analysis and the results of verification tests have shown that this new method is reliable, and it will provide guidance in academic research and engineering application of the spherical indentation strain-gauge method.     

Numerical investigation on radial impeller induced vortex rope in draft tube under partial load conditions

The vortex rope phenomena appearing in a draft tube under partial load operations were investigated. The efforts were carried out by using a homogeneous equilibrium vapor-liquid two-phase model and a blending SST turbulence model, and the former takes account of the weak compressibility of mixed media. The vortex rope phenomena were induced by the radial impeller and three kinds of flow regimes were illustrated. Vortex rope was visible at some conditions and it displayed various patterns, while no obvious vortex rope was found under some conditions. It was found that the plant cavitation number determines that whether the vortex rope was visible or invisible. An interesting profile was that a secondary vortex filament ring entwining the vortex rope appeared clearly near the design condition. Both flow structures and pressure characteristics were studied to depict the vortex mechanism and the characteristics of the η-σ curves. Further analysis found that the shedding frequency of the vortex ring is similar with that of the precession movement.     

Generalized model of vibro-isolation systems with seated human body for single-axis transmission of vibration

A generalized model of vibration isolation systems with a human body in a seated position is developed. The system dynamics is modeled for a single-axis transmission of vibration, that is, longitudinal x, lateral y and vertical z, to limit whole-body vibration exposure. The developed model can be successfully employed to describe the propagation of vibration waves from the source to a vibrating object. The proposed mathematical model can be widely used to protect a human body against vibration.     

Estimation of ambient temperature impact on vertical dynamic behaviour of passenger rail vehicle with damaged wheels

Maintenance and repair specialists of rolling stock face the problem related to accurate and reliable assessment of the vibrations of the car body of passenger rail vehicle, caused by wheel damage, and its impact on passengers. Another important aspect is to deter-mine the permissible speed at which the passenger car with wheel damage could move to the nearest station or depot without badly damaging the rails. The purpose of this research is to examine the dynamic processes of the interaction of the passenger car chassis with the railway track using a newly developed mathematical models called the “Passenger Car - Track” system. During the simulation, the dynamic characteristics of the track, bogies and car body in different season temperature were estimated. The validation of theoretical results was obtained based on the field tests of the test train as well as the results of measurements of changes in track stiffness temperatures. Finally, conclusions and suggestions are presented.     

Compound fault diagnosis of bearings using improved fast spectral kurtosis with VMD

The fast spectrum kurtosis (FSK) algorithm can adaptively identify resonance bands of a signal, and fault characteristics can be extracted by analyzing the selected frequency bands. However, in practical applications, the bearing failure may be composed of various faults (inner ring/outer ring/rolling element) and the faults may be located in different resonant bands. Due to the interference between different fault components and noise, the weak components may be submerged when FSK is used to deal with compound fault signals. To improve the accuracy of an FSK processing compound fault located in different resonance bands, an improved FSK method combined with the variational mode decomposition (VMD) is proposed. First, the parameters (number of components K / penalty factor α ) in the VMD decomposition are selected, and the original compound fault signal is preprocessed by VMD decomposition, so that the original signal is decomposed into K variational intrinsic mode function (VIMF) components. The resonance center bands of these signals are different from each other, so the different fault information is located in different VIMF. Finally, each VIMF component is calculated by FSK. Through the simulated and experimental analysis, the method can accurately identify the resonance bands, and identify the weak fault characteristics of compound bearing fault.     

Optimization of excitation frequency and guided wave mode in acoustic wavenumber spectroscopy for shallow wall-thinning defect detection

In plate-like structures, wall-thinning defects resulting from corrosion may not be accompanied by any indication of damage on the surface. Thus, inspections are required to ensure that wall-thinning defects are within allowable limits. However, conventional ultrasonic techniques require physical contact to the structure. Alternatively, acoustic wavenumber spectroscopy (AWS) may be used for detecting, locating, and characterizing defects. This paper describes the performance of AWS in the estimation of a wall-thinning defect size in thinplate structures using finite element analysis (FEA). Through a series of FEAs, the structure’s steady-state response to a single-tone ultrasonic excitation is simulated, and the wall-thinning defect-size effect on the wavenumber-estimation accuracy is investigated. In general, the A0 guided wave mode is widely used to visualize defects because of the nature of the wave speed variation in relation to the plate thickness. However, it is not appropriate for the detection of relatively shallow wall-thinning defects, because the rate of change in wave speed with the thickness decreases with increasing plate thickness. To overcome this limitation, we propose a method to optimize excitation frequency and effective guided wave mode instead of utilizing the A0 mode. The results can be used to determine the size of shallow wall-thinning defects in plate-like structures.     

Reducing undesirable vibrations of planar linkage mechanism with joint clearance

An optimization design method is presented to reduce the undesirable vibrations caused by clearance for planar linkage mechanism. A clearance joint is defined and considered a contact/impact force constraint. Contact and impact force models for the clearance joint are established using a normal contact force model based on Hertz model with energy loss and a tangential friction model based on modified Coulomb model with dynamic friction coefficient, respectively. In view of the clearance joint, dynamic equations and optimization method for a planar four-bar mechanism are then presented as an application example. The optimization aims to minimize the maximum absolute acceleration peaks of the mechanism by determining the link lengths of the planar linkage mechanism. Finally, the optimization design is solved by a generalized reduced gradient algorithm. Results show evident decrease in vibration peaks of the mechanism and obvious reduction in the contact forces in the clearance joint, which contribute to a good performance of planar linkage mechanism systems.     

Measurement of residual stress using linearly integrated GMR sensor arrays

Tubular-type transmission towers have several advantages, but could be compromised if welding defects from the construction process are not found during deployment. This research derived an equation that illustrates how a change in stress accompanied with mechanical deformation triggered a change in distribution of magnetic flux density. Furthermore, it verified experimentally that a change in distribution of magnetic flux density occurred due to a change in stress at the welding zone. Using this principle, this research proposes a system to measure residual stress occurred in the welding zone of tubular-type transmission tower. The ultrasound examination results were compared and the result showed that ultrasound signals revealed defects in a place where sudden distribution of magnetic flux density was presented. However, when a number of welding defects occurred across the large area, the distribution of magnetic flux density may not change due to the alleviating effect of the stress concentration.     

Numerical investigation on residence time of cooling water and surface temperature distribution of water-cooled grates

Waste incineration is a treatment system that reduces waste volume while capturing or destroying potentially harmful substances and recovers energy and chemical contents from wastes. Grate incinerator is one of the thermal treatment methods in waste incinerations. The incineration grates are exposed to high heat flux due to the occurrence of combustion on their surface. Therefore, cooling the incineration grate is one of the main issues in these treatments. In this study, the conjugate heat transfer between the cooling water and incineration grate is investigated numerically. We consider different geometries of the internal guide vane in the cooling channel and analyze the effects of the shapes of the guide vane on the heat transfer performance in the incineration grate. We also calculate the fluid residence time in the cooling channel and investigate the relation between the heat transfer performance and residence time of the cooling fluid. Results confirm that the maximum residence time of the cooling fluid can be reduced, from which the heat transfer performance can be improved.