Seeded fault detection on helical gears with acoustic emission

Acoustic emission (AE) is one of many technologies for health monitoring and diagnosis of rotating machines such as gearboxes. Although significant research has been undertaken in understanding the potential of AE in monitoring gearboxes this has been solely applied to spur gears. This report presents an experimental investigation that assesses the effectiveness of AE in identifying seeded defects on helical gears; the first known attempt. Additionally vibration analysis has performed to study the effect of seeded defect on the vibration signature of the meshing gears.     

Energy Index technique for detection of Acoustic Emissions associated with incipient bearing failures

The application of Acoustic Emission (AE) technique to condition monitoring of gears and bearings is gaining significance as it can detect early symptoms of defects such as pitting, wear and flaking of surfaces. Such early detection of defects is of vital importance so as to avoid major failures with catastrophic consequences. This article presents results on the Energy Index (EI) technique, used in detecting masked AE signatures associated with the loss of mechanical integrity in bearings. Both simulated and real experimentally generated AE signatures were used to investigate the efficiency and applicability of the technique at signal-to-noise ratios as low as 0.25. In conclusion it is shown that the EI technique is effective in detecting AE burst buried in random noise thereby offering a complementary tool for the diagnostician.     

Noise Reduction in Spur Gear Systems

This article lists some tips for reducing gear case noise. With this aim, a static analysis was carried out in order to describe how stresses resulting from meshing gears affect the acoustic emissions. Different parameters were taken into account, such as the friction, material, and lubrication, in order to validate ideas from the literature and to make several comparisons. Furthermore, a coupled Eulerian–Lagrangian (CEL) analysis was performed, which was an innovative way of evaluating the sound pressure level of the aforementioned gears. Different parameters were considered again, such as the friction, lubrication, material, and rotational speed, in order to make different research comparisons. The analytical results agreed with those in the literature, both for the static analysis and CEL analysis—for example, it was shown that changing the material from steel to ductile iron improved the gear noise, while increasing the rotational speed or the friction increased the acoustic emissions. Regarding the CEL analysis, air was considered a perfect gas, but its viscosity or another state equation could have also been taken into account. Therefore, the above allowed us to state that research into these scientific fields will bring about reliable results.     

Effects of operating conditions on the Acoustic Emissions (AE) from planetary gearboxes

In the last decade, the use of acoustic emissions has received growing acceptance for its application in machine condition monitoring. This is because it offers good possibilities to diagnose failures at early stages and low rotational speeds. The use of acoustic emissions for condition monitoring of gears, however, is still an active field of research, because several questions remain unanswered. One of these questions is the effect of operating conditions on the AE generated during gear meshing. In this work, the results of experiments carried out on a non-faulty planetary gearbox test bench are presented. A planetary gearbox is considered, because of its usual application on machines subjected to variable operating conditions. The effects of lubricant temperature, load and rotational speed are investigated. The conclusions obtained from the experiments are used for the analysis of the AE measured on the planetary gearbox of a bucket wheel excavator.     

Observations of changes in acoustic emission waveform for varying seeded defect sizes in a rolling element bearing

The investigation reported in this paper was centered on the application of the acoustic emissions (AE) technology for characterising the defect sizes on a radially loaded bearing. An experimental test-rig was designed such that defects of varying sizes could be seeded onto the outer and inner races of a test bearing. The aim of this investigation was to correlate defect size with specific AE parameters and to ascertain the relationship between the duration of AE transient bursts associated with seeded defects to the actual geometric size of the defect. In addition, the use of AE to detect inner race defects was explored particularly as this known to be fraught with difficulty. It is concluded that the geometric defect size of outer race defects can be determined from the AE waveform.     

Crystal bridge formation marks the transition to rigidity in a thin lubrication film

We report that the rheological transition in a thin lubrication film of dodecane from bulk to high viscosity states as the thickness is decreased is the result of a novel structural transition. Using nonequilibrium molecular dynamics simulations we find that the initial increase in viscosity as the film thins is due to the formation of isolated crystalline bridges between the surfaces. As the thickness decreases further, these bridges increase in number and organize themselves into a tetratic order in the plane of the surface. We show that this ordered state melts at a temperature of 350 K.     

Condition monitoring of worm gears

Condition monitoring of key components in rotating machines such as gearboxes ensure reduction in costly unscheduled machine down time. This paper explores the possibility of monitoring seeded defects on worm gears with acoustic emission, and, comparisons are made with vibration analysis. Unlike other types of gearboxes, monitoring of worm gearboxes is not widely documented. It is shown that AE offers better diagnostic capability than vibration analysis.     

A history of neutrons and nuclei. Part 2

The application of physical principles in some studies of lubrication and wear is described. The states of boundary and hydrodynamic lubrication are contrasted and the importance of identifying the state of lubrication of a system is emphasized. Experiments which demonstrate that the lubrication of gears and roller bearings is essentially hydrodynamic are described and the consequences of solid-solid contacts through the hydrodynamic film are discussed. The function of boundary additives such as are present in E.P. oils in mitigating the damage consequent upon solid-solid encounters is described and so is the influence upon damage of the surfaces themselves. Lastly the importance is indicated of wear experiments conducted without lubrication. Such experiments have a relevance to solid-solid encounters through hydrodynamic films and are of direct application to systems in which fluid lubrication cannot be tolerated.

So often a little oil suffices to still a squeal or to restore a neglected machine to use that sometimes, without conscious effort, the scientific interest of lubrication and wear and their economic importance pass unmarked.     

离子注钇对镍900℃高温氧化行为及氧化膜性能的影响研究

采用热重分析对纯镍及其表面离子注钇样品在900℃空气中的恒温氧化动力学规律进行了研究.用扫描电子显微镜和透射电子显微镜对含钇和不含钇氧化膜的微观形貌及结构进行了观测.用声发射方法对氧化膜在恒温生长阶段和空冷阶段的开裂与剥落进行了实时监测，根据相应的氧化膜开裂模型，对声发射信号在时域和数域上的分布情况进行了分析.结果表明离子注钇显著降低了镍的恒温氧化速率，提高了表面NiO膜的抗开裂和抗剥落性能.离子注钇提高镍抗氧化性能的原因主要是钇细化了表面NiO膜的晶粒、提高了氧化膜的高温塑性和蠕变能力，并显著降低了Ni/NiO界面缺陷的数量和大小. 关键词： 高温氧化 应力 声发射 离子注入     

Contact ratio of rough surfaces with multiple asperities in mixed lubrication at high pressures

Relative optical intensity interference was used to measure the lubrication film thickness when four kinds of polyalphaolefin (PAO) were used as lubricants confined between a smooth sapphire disc surface and a rough steel ball surface. Maximum Hertz contact pressure up to 3 GPa was applied in the central part of the contact region in mixed lubrication. It was found that the contact ratio (the ratio of real contact region to the whole nominal contact region) is related to the film thickness, the applied pressure, the surface roughness and the rolling speed, and so on. Contact ratio evidently reduces as lubrication film thickness or rolling speed increases. Quantitative relationship between the contact ratio and the influence factors was summarized based on the nonlinear fitting of experimental measurements. A formula was put forward to calculate the contact ratio at high pressure conditions according to the current experimental results.     

GaN薄膜的热导率模型研究

准确预测GaN半导体材料的热导率对GaN基功率电子器件的热设计具有重要意义.本文基于第一性原理计算和经典Debye-Callaway模型,通过分析和完善Debye-Callaway模型中关于声子散射率的子模型,建立了用于预测温度、同位素、点缺陷、位错、薄膜厚度、应力等因素影响的GaN薄膜热导率的理论模型.具体来说,对声子间散射项和同位素散射项基于第一性原理计算数据进行了系数拟合,讨论了两种典型的处理点缺陷和位错散射的散射率模型,引入了应用抑制函数描述的各向异性边界散射模型,并对应力的影响进行了建模.热导率模型预测值和文献中典型实验数据的对比表明,基于第一性原理计算数据拟合的热导率模型和实验测量值总体符合较好,300 K温度附近热导率数值及其随温度变化的趋势存在20%左右的偏差.结合实验数据和热导率模型进一步确认了第一性原理计算会高估同位素散射的影响,给出了薄膜热导率随薄膜厚度、位错面密度、点缺陷浓度的具体变化关系,同位素和缺陷散射会减弱薄膜热导率的尺寸效应,主要体现在100 nm附近及更小的厚度范围.     

渐开线斜齿轮短齿廓修形降噪分析*

为了降低特定工况下减速箱的噪声特性,找到相对最佳的渐开线斜齿轮修形方式,该文基于专业的齿轮修形软件Kisssoft和多学科一体化软件LMS Virtual Lab,根据短齿廓修形可以改变渐开线斜齿轮的端面、轴向重合度的原理,比较了未修形和经过不同短齿廓修形方式达到特定重合度后的渐开线斜齿轮减速箱声功率级的大小。分析了经过短齿廓修形后的减速箱声功率级在转速500~2000 r/min之间显著下降的原因,并对经过短齿廓修形后的减速箱声功率级在2500 r/min和3000 r/min时并未明显下降的原因做了解释。最后根据减速箱声功率级在转速500~2000 r/min之间的平均降幅,认为通过齿形鼓形修形使得渐开线斜齿轮的端面、轴向重合度分别为1.516、0.864时,减速箱声功率级降幅最大,降噪效果最好。     

Atomic simulation of AlGaN film deposition on AlN template

In this article, we study the deposition of AlGaN film on AlN template by molecular dynamics (MD) simulations. The effects of growth temperature and film thickness on the dislocation of deposited AlGaN film are simulated and studied. The atomic structure of deposited AlGaN film is also investigated. We find that the dislocations usually occur at the interface between AlN template and AlGaN film and then extend towards the growth direction. The dislocation density decreases with the increase of AlGaN film thickness, which indicates that increasing the thickness of deposited AlGaN film to a certain extent is beneficial to reducing dislocation. In addition, increasing the growth temperature can also effectively reduce the dislocation in deposited AlGaN film. Furthermore, the crystallinity of deposited AlGaN film could be improved by increasing the growth temperature. This is consistent with the dislocation discussion. The mobility of adatoms increases as the growth temperature increases. So it is easier for adatoms to find their ideal lattice points at higher temperature. Thus the dislocation and other defects can be effectively reduced and the crystal quality of deposited AlGaN film could be improved.     

Nonlinear dynamics of planetary gears using analytical and finite element models

Vibration-induced gear noise and dynamic loads remain key concerns in many transmission applications that use planetary gears. Tooth separations at large vibrations introduce nonlinearity in geared systems. The present work examines the complex, nonlinear dynamic behavior of spur planetary gears using two models: (i) a lumped-parameter model, and (ii) a finite element model. The two-dimensional (2D) lumped-parameter model represents the gears as lumped inertias, the gear meshes as nonlinear springs with tooth contact loss and periodically varying stiffness due to changing tooth contact conditions, and the supports as linear springs. The 2D finite element model is developed from a unique finite element-contact analysis solver specialized for gear dynamics. Mesh stiffness variation excitation, corner contact, and gear tooth contact loss are all intrinsically considered in the finite element analysis. The dynamics of planetary gears show a rich spectrum of nonlinear phenomena. Nonlinear jumps, chaotic motions, and period-doubling bifurcations occur when the mesh frequency or any of its higher harmonics are near a natural frequency of the system. Responses from the dynamic analysis using analytical and finite element models are successfully compared qualitatively and quantitatively. These comparisons validate the effectiveness of the lumped-parameter model to simulate the dynamics of planetary gears. Mesh phasing rules to suppress rotational and translational vibrations in planetary gears are valid even when nonlinearity from tooth contact loss occurs. These mesh phasing rules, however, are not valid in the chaotic and period-doubling regions.     

Numerical study on reducing the vibration of spur gear pairs with phasing

A new method of reducing gear vibration was analyzed using a simple spur gear pair with phasing. This new method is based on reducing the variation in mesh stiffness by adding another pair of gears with half-pitch phasing. This reduces the variation in the mesh stiffness of the final (phasing) gear, because each gear compensates for the variation in the other's mesh stiffness. A single gear pair model with a time-varying rectangular-type mesh stiffness function and backlash was used, and the dynamic response over a wide range of speeds was obtained by numerical integration. Because of the reduced variation in mesh stiffness and the double frequency, the phasing gear greatly reduced the dynamic response and nonlinear behavior of the normal gears. The results of the analysis indicate the possibility of reducing vibration of spur gear pairs using the proposed method.     

单晶硅薄膜面向热导率分子动力学研究

采用非平衡分子动力学方法(NEMD)研究了室温(300 K)下厚度为2～32 nm的单晶硅薄膜的沿膜平面方向的热导率,并使用Debye-Einstein模型对模拟温度进行了量子修正。模拟表明薄膜面向热导率小于相应的大体积值,并随膜厚度减小而减小,具有显著的尺寸效应。在模拟范围内膜面向热导率略大于其法向热导率;与声子气动力论的定性结果一致。晶体的表面弛豫和表面重构现象导致了MD模拟中体系总内能的升高。     

Prediction of airborne radiated noise from lightly loaded lubricated meshing gear teeth

This paper introduces a novel analytical method for determination of gear airborne noise under lightly loaded conditions, often promoting gear rattle of loose unengaged gear pairs. The system examined comprises a single gear pair, modelled through integrated contact tribology and inertial transient dynamics. Lubricant film thickness, structural vibration and airborne gear noise are predicted and correlated with experimental measurements undertaken in a semi-anechoic environment. Good agreement is noticed between the numerical predictions and the experimental measurements. The presented model is capable of estimating the airborne radiated gear noise levels and the dynamic behaviour of gear pairs under different operating conditions, with superimposed impulsive input speed harmonics.     

Three-dimensional nonlinear vibration of gear pairs

This work investigates the three-dimensional nonlinear vibration of gear pairs where the nonlinearity is due to portions of gear teeth contact lines losing contact (partial contact loss). The gear contact model tracks partial contact loss using a discretized stiffness network. The nonlinear dynamic response is obtained using the discretized stiffness network, but it is interpreted and discussed with reference to a lumped-parameter gear mesh model named the equivalent stiffness representation. It consists of a translational stiffness acting at a changing center of stiffness location (two parameters) and a twist stiffness. These four parameters, calculated from the dynamic response, change as the gears vibrate, and tracking their behavior as a post-processing tool illuminates the nonlinear gear response. There is a gear mesh twist mode where the twist stiffness is active in addition to the well-known mesh deflection mode where the translational stiffness is active. The twist mode is excited by periodic back and forth axial movement of the center of stiffness in helical gears. The same effect can occur in wide facewidth spur gears if tooth lead modifications or other factors such as shaft and bearing deflections disrupt symmetry about the axial centers of the mating teeth. Resonances of both modes are shown to be nonlinear due to partial and total contact loss. Comparing the numerical results with gear vibration experiments from the literature verifies the model and confirms partial contact loss nonlinearity in experiments.     

Thermodynamics approach of the formation of Ni catalyst particles for carbon nanotubes growth

Size-dependent thermodynamic parameters, such as Gibbs free energy, enthalpy and entropy, for the transition of a Ni nanofilm to catalyst particles for subsequent carbon nanotube growth have been explored. In this investigation, we consider the derived equations of the size-dependent melting temperature of nanosolids based on our previous works. Using this thermodynamic approach, it is found that the diameter of Ni particles is 3 times greater than the thickness of the original film. From the critical and stable sizes of transformed Ni nanoparticles, a minimum film thickness for transformation of film to nanoparticles was obtained. Our predictions are in good agreement with experimental results.     

Gear transmission dynamics: Effects of index and run out errors

This work describes a non-linear dynamic model for the study of the vibration signals generated by gear transmissions. The developed model considers both the parametric excitations due to the variable compliance of bearings and gears, can handle changes in the transmitted torque and allows the integration of the dynamic equations quickly and accurately. This model has been developed previously by the authors to assess the profile deviations on the dynamic behavior of gear transmissions and its influence on the transmitted torque. It also includes the presence of gear defects as cracks and pitting during the calculation of meshing forces. In this paper, the model has been enhanced in order to include two common defects such as index errors and run out or eccentricity errors. Index errors occur as a result of a non-uniform angular distribution of the tooth profiles along the pitch circle. Run out appears due to the displacement of the geometric center of the gear with respect to the center of rotation of the shaft on which it is mounted. Although both errors are caused by different reasons, sometimes they have been confused because of their similitudes. The procedure for including both kinds of errors in the model is described and simulations under several transmitted torques are presented. The results are assessed and compared focusing the attention on certain transmission parameters and magnitudes as transmission error, load forces in the tooth flanks and demodulation techniques on the resulting vibratory signals.