Académique Documents
Professionnel Documents
Culture Documents
2 (2015) 176-185
Tribology in Industry
RESEARCH
www.tribology.fink.rs
Keywords: ABSTRACT
Roller Bearings
This paper describes the comparison between Vibration Analysis (VA) and
Characteristic defect frequency
Acoustic Emission (AE) method to predict the defect severity in rolling element
Vibration analysis
bearings with respect to the gradual increase of defect size. In bearing fault
Acoustic emission
diagnosis vibration based methods are very popular, but the signals acquired by
its transducers from the bearings are distorted by other faults and mechanical
Corresponding author: noise from the equipment. Vibration based methods are effective when the defect
V. Vital Rao in the bearings has already become severe. AE is a non destructive testing (NDT)
technique used in structural health monitoring and its application for bearing
Engineering Shops Department,
defect diagnosis is gaining momentum as an alternate diagnostic tool because of
Visakhapatnam Steel Plant, its inherent high signal-to-noise-ratio (SNR). A bearing test rig was designed and
Visakhapatnam, AP, India. set up to study the various defects in rolling element bearings in real
E-mail: vvrao_vana@yahoo.co.in environment. In earlier cases, though the researchers studied on different types
of seeded defects with random sizes, they could not ascertain the correlation
between their defect sizes and the vibration amplitude. The experimental
investigation reported in this paper is centered on seeded defect of same type
with gradual increase of its size on outer race of radially loaded cylindrical roller
bearings and running the defective bearing at different speeds and loads. Data
acquired through AE & vibration probes simultaneously for better diagnosis.
Comparisons between AE and VA over a range of speed and load conditions at
gradual increase of defect size are presented and from them it is concluded that
AE method is superior to identify the severity of defect.
© 2015 Published by Faculty of Engineering
176
V.V. Rao and Ch. Ratnam, Tribology in Industry Vol. 37, No. 2 (2015) 176-185
bearing and gear faults has been gaining origin of damages at the contact between a PVD
importance in recent years because of its coating and a substrate in the body [12].
detrimental influence on the reliability of
equipment. Different techniques have been The interaction of surface asperities and
developed for monitoring and diagnosis of impingement of the bearing elements over the
rolling element bearings [6]. Most of the fault defect on the race pathway generates acoustic
detection methods are based on vibration signal emissions which are basically transient elastic
analysis and it is the commonly used technique waves. There have been numerous
employed in rotor-bearing systems. Todorovic investigations reported on applying AE to
Petar et al. [7] studied vibration analysis of bearing defect diagnosis. Some investigators
cracked rotor system to find out the fatigue [13-15] have shown that certain AE
cracks. Detection of the fault and its severity are parameters identified bearing defects before
two important steps or features of a condition they appeared in the vibration acceleration
monitoring system. Lifetime of a machine range. In addition to this, successful
component is determined by the severity of the applications of AE to bearing diagnosis on
fault. It is crucial, especially in critical systems, extremely slow rotational speeds have been
where continual operation is generally reported [16,17]. The modulation of AE
indispensable. The bearing defects can be either signatures at bearing defect frequencies has
distributed or local type or combination of both. also been observed by other researchers [18-
The distributed defects can be due to surface 21]. AE components such as time and
roughness, waviness, misaligned races, and off- frequency in highly transient signals are very
size rolling elements. Localized defects are much dependent on each other. This prompted
developed in the raceways, rollers and cage of a many researchers to work on automatic defect
bearing. The periodic impacts occur at ball- identification using wavelet algorithm [22,23].
passing frequency (characteristic defect Abdullah et al. [24] reported relationship
frequencies), which can be estimated from the between AE R.M.S. amplitude and kurtosis for
bearing geometry and the rotational speed [8]. a range of defect conditions and relationship
The vibration signal is not sensitive to the between the defect size and AE burst duration.
incipient defects in the bearings; sometimes the In this paper the bearing kinematics, bearing
defect frequencies are not observable with the testing facility and the details of experimental
help of the Fast Fourier Transform (FFT) investigation of both acoustic emission and
spectrum, because the impulses generated by the vibration analysis on test bearings
defects are masked or distorted by the noise simultaneously for various defect sizes in
generated by other parts of the equipment. To outer race are reported and the results
overcome this problem, advanced signal obtained are thoroughly discussed.
processing techniques are implemented by many
researchers to detect bearing local faults [9].
2. BEARING KINEMATICS
Acoustic emissions are actually defined as
transient elastic waves generated from a rapid When a faulty bearing is in use, the rolling
release of strain energy caused by a deformation element comes across the defect, it hits the edge
or damage within or on the surface of a material of the defect and produces impulse in the races.
[10]. AE was originally developed for non- The periodic impulses produce certain
destructive testing of static structures; however frequencies (Characteristic defect frequencies).
its applications have now been extended to These frequencies depend on bearing
condition monitoring of rotating machines. kinematics, its geometry and speed.
During the last few years, a significant progress
in the capabilities of acoustic instrumentation The Fig. 1 shows schematic of a typical angular
together with the signal processing techniques contact rolling element bearing. As a general
has made it possible to extract useful diagnostic case; it will be initially assumed that both inner
information from acoustic signals. AE signals are and outer races rotate in a bearing which has a
used in tribological studies to study the friction common contact angle and no skidding of rolling
and wear of coated machine components [11]. elements between the races.
AE analysis, gives valuable information about
177
V.V. Rao and Ch. Ratnam, Tribology in Industry Vol. 37, No. 2 (2015) 176-185
1 d cos
N f i 1 f o 1 d cos f o (9)
2 Dp
D p
d cos (10)
N
fi f o 1
2 Dp
Fig. 1. Schematic diagram of bearing geometry.
In the similar way Ball Pass Frequency of the
ν, ω, f, r - refers to linear speed, angular speed, Inner race (BPFI) can be evaluated multiplying
frequency and radius. the number of rolling elements with the relative
Subscripts: i, o, c, r – refers to inner race, outer angular speed between cage and inner race:
race, cage and rolling element. BPFI N i c (11)
Dp - Pitch circle diameter; d -Diameter of the
rolling element; θ -Contact angle; N - Number d cos (12)
of rolling elements.
N
fi f o 1
2 Dp
The cage linear speed can be given by The frequency of rotation of the rolling elements
about their own axes Ball Spin Frequency (BSF),
vi vo i ri o ro can also be derived. The frequency of rotation,
vc (1)
2 2 assuming no slip, is given by the frequency of
rotation of the cage with respect to the inner
Dp
rc (2) race multiplied with the diameter ratio of the
2 inner race to the ball diameter.
Dp d cos (3)
ri The ball or roller angular speed rotating on its
2 2
own centre is given as follows:
Dp d cos (4)
ro vr
2 2 r (13)
rr
From the above equations, the cage angular speed:
The ball or roller tangential speed at the contact
v point with the inner race is:
c c (5)
vr i c ri , r i c ri
rc
(14)
rr
1 d cos d cos
c i 1 o 1 (6)
2 D p
D p d cos
2
(15)
Dp
BSF f r fi f o 1
D
2d
c 2f c p
178
V.V. Rao and Ch. Ratnam, Tribology in Industry Vol. 37, No. 2 (2015) 176-185
These calculated frequencies obtained may to control speed, and a vertical hydraulic ram for
slightly vary from the actual values due to applying load radially. The operational speed
slipping or skidding of rolling elements [25]. range is up to 2800 rpm with a maximum load
Some researchers [26] mentioned that it is capability of 16 kN via a hydraulic ram. On one
difficult to obtain a significant peak at these end of the shaft a V-pulley and on the other end
defect frequencies in the direct vibration a test bearing with housing is assembled. The
spectrums obtained from a defective bearing. shaft is supported by two bearings with plumber
This is due to the fact that noise or vibration from blocks. Deep groove ball bearings (SKF 6212
other sources masks the vibration signal from the RS2) concealed on both sides are used as
bearing unless the defect is sufficiently large. support bearings. The motor drives the shaft
with a V-belt. The motor is mounted on a
separate base frame to avoid transfer of
3. EXPERIMENTAL SETUP vibration to test rig. The test bearing block is
square split housing and is made of EN 24 steel
A bearing test rig is designed and setup to fulfill material. On top of split housing, AE probe,
the requirements of current investigation and vibration accelerometer and hydraulic ram are
future research in this area. The schematic of the placed while conducting the test run.
test rig is shown in Fig. 2. The testing involves
mounting and running the defective bearing
along with acquisition of AE and vibration signal 4. EXPERIMENT METHODOLOGY
data under various speed and load conditions.
In this investigation N 312 type cylindrical roller
bearing with normal clearance is used (Fig. 4).
The geometric details of the test bearing are,
Inner diameter- 60 mm, Outer diameter- 130
mm, Width- 33 mm, Number of rollers- 12,
Rolling element diameter- 18 mm, Pitch circle
diameter (Dp )- 96 mm, Contact angle (θ)- 00.
The reason for selection of this bearing is that it
allows easy assembly and dismantling of outer
race and defect creation for investigation.
179
V.V. Rao and Ch. Ratnam, Tribology in Industry Vol. 37, No. 2 (2015) 176-185
180
V.V. Rao and Ch. Ratnam, Tribology in Industry Vol. 37, No. 2 (2015) 176-185
181
V.V. Rao and Ch. Ratnam, Tribology in Industry Vol. 37, No. 2 (2015) 176-185
Theoretic
Differe
al BPFO
2 kN Load 4 kN Load
nce in
RPM dB Actual dB Actual BPFO
value BPFO value BPFO
1300 1.57 1.66 2.27 2.45 2.17 1.84 2.11 2.40 2.66 2.91
Table 2. Acoustic Emission amplitude (dB level) at
1500 2.01 2.01 2.90 2.97 2.57 2.09 2.43 2.70 3.02 3.28
defect frequencies, 2 kN load.
0.5 mm width defect at
Without defect
outer race The variations of AE amplitudes and vibration
RPM RMS velocities with respect to gradual increase
FTF BSF BPFI BPFO FTF BSF BPFI BPFO
of defect size of all test runs are compared and
500 0.11 0.25 0.26 0.29 0.57 0.18 0.13 1.14
presented in Tables 4 and 5 and the trends are
700 0.07 0.17 0.11 0.30 0.68 0.76 0.35 1.46
shown in graphs Figs. 6-7. In VA the overall RMS
900 0.15 0.35 0.56 0.46 0.31 0.77 0.57 2.16 velocity gradually increases with increase in
1100 0.07 0.32 0.27 0.24 0.28 0.43 0.09 2.89 defect size, load and speed, but the variations
1300 0.06 0.52 0.54 0.35 0.26 0.51 0.24 3.21 are not significant. The same trends are also
1500 0.17 0.58 0.28 0.15 0.56 0.55 0.04 3.52 observed in AE analysis, but the incremental
182
V.V. Rao and Ch. Ratnam, Tribology in Industry Vol. 37, No. 2 (2015) 176-185
183
V.V. Rao and Ch. Ratnam, Tribology in Industry Vol. 37, No. 2 (2015) 176-185
were captured by the AE probe, but vibration Fourier coefficients', Journal of sound and
accelerometer is unable to capture these due to vibration, vol. 303, pp. 909-917, 2007.
its low frequency range. In all AE frequency [3] Ch. Ratnam and B.S. Ben, 'Structural damage
spectra it is observed that the peaks raised at detection using combined finite element and
BPFO and maximum amplitude recorded, but model lamb wave propagation parameters',
this is not the case in vibration spectrums. Journal of mechanical science, vol. 223, pp. 769-
777, 2009.
[4] P.S. Rao and Ch. Ratnam, 'Vibration based
6. CONCLUSION damage identification using Burg’s algorithm
and Stewart control charts', Journal of ASTM
In this paper the results of present investigation International, vol. 8, no. 4, 2011.
are presented, which is an attempt made to find [5] S.W. Doebling, C.R. Farrar and M.B. Prime, 'A
out the practical AE and vibration response with summary review of vibration based damage
gradual increase of defect size in bearing outer identification methods', Shock and Vibration
race. Time waves and frequency spectrums of Digest, vol. 30, no. 3, pp. 91–105, 1998.
both methods (bearing without defect and with [6] N. Tandon and A. Choudhury, 'A review of
defects) are analyzed. There is significant Vibration and Acoustic measurement methods
difference in vibration and acoustic emission for the detection of defects in rolling element
spectrums. In vibration analysis, overall RMS bearings', Tribol. Int., vol. 32, no.8, pp. 469-80,
velocity increases with the increase in RPM and 1999.
load. The same trend is observed with increase
[7] Todorovic Petar, Jeremic Branislav, Macuzic
in the defect size. From vibration time waves it Ivan, Brkovic Aleksandar and Proso Uross,
can be concluded that there is a defect in outer 'Vibration analysis of cracked rotor during run-
race but the severity of the defect could not be up', Tribology in Industry, vol. 30, no. 1&2, pp.
ascertained. 55-62, 2008.
[8] P.D. McFadden and J.D. Smith, 'Vibration
In AE analysis the frequency spectrum clearly monitoring of rolling element bearings by the
shows the defect frequency and subsequent high-frequency resonance technique- a review',
super harmonics. The dB value also increases Tribology International, vol. 17, no. 1, pp. 3-10,
along with RPM, load and defect size. From the 1984.
AE time wave the energy released at each impact
[9] LabVIEW, Advance Digital Signal Processing
can be clearly observed. The area under the User Manual, Austin, 2007.
curve shows the impact which increases with
increase in defect size. Hence from these [10] J.R. Mathew, Acoustic Emission. Gordon and
experimental investigations it is revealed that Breach Science Publishers Inc., New York, 1983.
AE technique is superior to vibration technique [11] N.K. Myshkin and D.V. Tkachuk, 'Tribology
and gives better analysis to diagnose the defects Development in Russia and Belarus', Tribology
in bearings. Also AE technique is found useful to in Industry, vol. 31, no. 1-2, pp. 3-7, 2009.
characterize and to find out the size of the [12] A. Minewitsch, 'Some Developments in
defect. In continuation of this investigation a Triboanalysis of Coated Machine Components',
mathematical model is being developed to study Tribology in Industry, vol. 33, no. 4, pp. 153-158,
the influence of all the seeded defects on the 2011.
behavior of the said bearing theoretically to [13] T. Yoshioka and T. Fujiwara, 'New acoustic
correlate the experimentally obtained results. emission source locating system for the study of
rolling contact fatigue', Wear, vol. 81, no. 1, pp.
183–186, 1982.
REFERENCES [14] T. Yoshioka and T. Fujiwara, 'Application of
acoustic emission technique to detection of
[1] E.P. Carden and P. Fanning, 'Vibration based rolling bearing failure', American Society of
condition monitoring: a review', Structural Mechanical Engineers, vol. 14, pp. 55–76, 1984.
Health Monitoring, vol. 3, no. 4, pp. 355–377,
2004. [15] D. Mba, R.H. Bannister and G.E. Findlay,
'Condition monitoring of low-speed rotating
[2] Ch. Ratnam, J. Srinivas and B.S.N. Murthy, machinery using stress waves, Parts I and II',
'Damage detection in mechanical systems using
184
V.V. Rao and Ch. Ratnam, Tribology in Industry Vol. 37, No. 2 (2015) 176-185
185