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Article
Publication date: 7 August 2018

Bhumi Ankit Shah and Dipak P. Vakharia

The purpose of this study is to identify the crack in the shaft at incipient stage. Transverse crack is the most common type of crack found on the periphery of the shaft. The…

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Abstract

Purpose

The purpose of this study is to identify the crack in the shaft at incipient stage. Transverse crack is the most common type of crack found on the periphery of the shaft. The changes in dynamic behaviour of the rotor at high speed are enormous. The reliable operation of the machinery is paramount for the safety of individual and plant. Condition-based maintenance monitors the mechanical and operational condition of the machine. During such inspection, if any unhealthy symptoms are detected, then affected part is identified and taken out for the maintenance at most appropriate time.

Design/methodology/approach

Simulating the transverse crack of different depth and location is the most challenging part of the experimental analysis. To optimize the total experimental cost for simulation of crack in the shaft, inverted crack is proposed to be produced in shaft and investigation shall be carried out for of early crack detection in shaft using vibration analysis. The set of experiments has been conducted on healthy shaft, inverted cracked shaft and actual cracked shaft. Inverted crack methodology provides flexibility of simulating crack of any size and at any location, and it can be reconfigured for several times to obtain various set of results.

Findings

To derive objective of the study, steady state response analysis and transient response analysis are performed on the experiment test rig. Vibration signals are acquired from the bearing locations to detect the crack. The paper addresses the influence of the inverted crack on critical speed of the shaft and deviation of first and second harmonic component of the shaft because of introduction of inverted crack. The resultant Nyquist plots, orbit plots and frequency plots are compared with the baseline data (obtained with the healthy shaft) to identify the crack.

Originality/value

The present study focuses on methodology by which inverted crack is developed in the healthy shaft, which resembles the behaviour of actual crack, and it shall be used to study the changes in rotor stiffness caused by transverse crack. The experimental results obtained using the inverted crack shaft have same vibration characteristics but in reverse direction as it would have occurred with the cracked shaft.

Details

Industrial Lubrication and Tribology, vol. 70 no. 7
Type: Research Article
ISSN: 0036-8792

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Article
Publication date: 10 April 2019

Bhumi Ankit Shah and Dipak P. Vakharia

Many incidents of rotor failures are reported due to the development and propagation of the crack. Condition monitoring is adopted for the identification of symptoms of the crack…

211

Abstract

Purpose

Many incidents of rotor failures are reported due to the development and propagation of the crack. Condition monitoring is adopted for the identification of symptoms of the crack at very early stage in the rotating machinery. Identification requires a reliable and accurate vibration analysis technique for achieving the objective of the study. The purpose of this paper is to detect the crack in the rotating machinery by measuring vibration parameters at different measurement locations.

Design/methodology/approach

Two different types of cracks were simulated in these experiments. Experiments were conducted using healthy shaft, crack simulated shaft and glued shaft with and without added unbalance to observe the changes in vibration pattern, magnitude and phase. Deviation in vibration response allows the identification of crack and its location. Initial data were acquired in the form of time waveform. Run-up and coast-down measurements were taken to find the critical speed. The wavelet packet energy analysis technique was used to get better localization in time and frequency zone.

Findings

The presence of crack changes the dynamic behavior of the rotor. 1× and 2× harmonic components for steady-state test and critical speed for transient test are important parameters in condition monitoring to detect the crack. To separate the 1× and 2× harmonic component in the different wavelet packets, original signal is decomposed in nine levels. Wavelet packet energy analysis is carried out to find the intensity of the signal due to simulated crack.

Originality/value

Original signals obtained from the experiment test set up may contain noise component and dominant frequency components other than the crack. Wavelet packets contain the crack-related information that are identified and separated in this study. This technique develops the condition monitoring procedure more specific about the type of the fault and accurate due to the separation of specific fault features in different wavelet packets. From the experiment end results, it is found that there is significant rise in a 2× energy component due to crack in the shaft. The intensity of a 1× energy component depends upon the shaft crack and unbalance orientation angle.

Details

International Journal of Quality & Reliability Management, vol. 36 no. 6
Type: Research Article
ISSN: 0265-671X

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