Lab Report 08

Applying non-destructive analysis techniques for assets health

assessment using predictive maintenance strategy.

1. Objectives
Ø To apply the Non-destructive analysis techniques.
Ø To use the predictive maintenance strategy.
Ø To demonstrate applications of vibration analysis
Ø To identify different kind of machine Failures.

2. Assigned machine

Turret lathe was the machine assigned to us as follow:

Fig. 1 Turret Lathe

3. Theory
Ø Factor causing vibration in a Turret Lathe:

1. Imbalance - A "heavy spot" in a rotating component will cause vibration when the
unbalanced weight rotates around the machine's axis, creating a centrifugal force. Imbalance
could be caused by manufacturing defects (machining errors, casting flaws) or maintenance
issues (deformed or dirty fan blades, missing balance weights). As machine speed increases
the effects of imbalance become greater. Imbalance can severely reduce bearing life as well
as cause undue machine vibration.
2. Misalignment /shaft runout - Vibration can result when machine shafts are out of line.
Angular misalignment occurs when the axes of (for example) a motor and pump are not
parallel. When the axes are parallel but not exactly aligned, the condition is known as parallel
misalignment. Misalignment can be caused during assembly or develop over time, due to
thermal expansion, components shifting or improper reassembly after maintenance. The
resulting vibration can be radial or axial (in line with the axis of the machine) or both.
3. Wear - As components such as ball or roller bearings, drive belts or gears become worn, they
might cause vibration. When a roller bearing race becomes pitted, for instance, the bearing
rollers will cause a vibration each time they travel over the damaged area. A gear tooth that is
heavily chipped or worn, or a drive belt that is breaking down, can also produce vibration.
4. Looseness - Vibration that might otherwise go unnoticed can become obvious and
destructive if the component that is vibrating has loose bearings or is loosely attached to its
mounts. Such looseness might or might not be caused by the underlying vibration. Whatever
its cause, looseness can allow any vibration present to cause damage, such as further bearing
wear, wear and fatigue in equipment mounts and other components.

Ø Vibrational Analysis
Vibration analysis is a process that monitors the levels and patterns of vibration signals
within a component, machinery or structure, to detect abnormal vibration events and to
evaluate the overall condition of the test object. The primary goal of vibration analysis is to
identify faults within a machine and then alert personnel that some type of action needs to
occur. Problems start to occur when the needed frequency of the data collection is not aligned
with the maintenance strategy

Fig 2. Graphical representation of vibrational Analysis

Ø Working procedure of vibrational Analysis :

Vibration analysis is a process that monitors vibration levels and investigates the patterns in
vibration signals. It is commonly conducted both on the time waveforms of the vibration signal
directly, as well as on the frequency spectrum, which is obtained by applying Fourier Transform
on the time waveform.Vibration can be measured through various types of sensors. Based on
different types of vibrations, there are sensors designed to measure displacement, velocity and
acceleration, with different measuring technologies, such as piezoelectric (PZT) sensors,
microelectromechanical sensors (MEMS), proximity probes, laser Doppler vibrometer and
many others.

Ø Uses and Applications

Vibration analysis is predominantly applied for the condition monitoring on machineries and
their key rotating parts, including but not limited to:
a) Bearings, gears, shafts, free wheels
b) Rotating machines such as gearboxes, motors, fans and drive-trains
c) Reciprocate machines such as piston engines, reciprocate compressors, pumps and door
mechanisms
Vibration analysis has also been employed in structural health monitoring, including but not
limited to:
• Bridges
• Pipes
• Turbine blades
Ø Advantages and disadvantages of Vibrational Analysis:

Advantages
1) Real-time reaction to the change of health conditions
2) Supports remote condition monitoring
3) Well-established processing and signal analysis methods/algorithms for predictive
maintenance
4) Supported by various sensors commercially available for different operational conditions
Limitations
1) Difficult to conduct fault localisation
2) Difficult to monitoring crack propagation
3) High requirements for proper system setup

Ø Displacement sensors:
A displacement sensor (displacement gauge) is used to measure travel range between where an
object is and a reference position. Displacement sensors can be used for dimension measurement
to determine an object's height, thickness, and width in addition to travel range.

The principle of laser displacement sensor ranging is a method where triangulation is applied by
combining the emitting element and the position sensitive device (PSD) to perform ranging
(detecting the amount of displacement).
The emitting element of Panasonic Industrial Devices SUNX's laser displacement sensors uses a
semi-conductor laser. The laser light is focused through the emitting lens and projected on an
object. At that time, some of the light beam that is reflected from the object produces a light spot
on the position sensing device. When the object moves, the PSD moves as well. Detecting the
changes in positions makes it possible to detect the
amount of displacement of Fig 3. Displacement sensors the object.
Some of the receiving elements use a linear

image sensor, and not the PSD. The PSD enables you to acquire information only about the
center position of the amount of light of the entire light spot. On the other hand, the emitting
elements with the linear image sensor detect the amount of light received by each cell.

Fig 4. Working of displacement sensors

Ø Velocity sensor
A velocity receiver (velocity sensor) is a sensor that responds to velocity rather than absolute
position. For example, dynamic microphones are velocityreceivers. Likewise, many electronic
keyboards used for music are velocitysensitive, and may be said to possess a velocity receiver in
each key.
Ø Accelerometer:
An accelerometer is a tool that measures proper acceleration. Proper acceleration is the
acceleration of a body in its own instantaneous rest frame; this is different from coordinate
acceleration, which is acceleration in a fixed coordinate system.
An accelerometer is an electronic sensor that measures the acceleration forces acting on an
object, in order to determine the object's position in space and monitor the object's movement.
Accelerometers can be used to measure vibration on cars, machines, buildings, process control
systems and safety installations. They can also be used to measure seismic activity, inclination,
machine vibration, dynamic distance and speed with or without the influence of gravity.

Fig 5. Accelerometer

Ø Vibrational Analysis on Turret Lathe:

When a lathe is machining heavy work piece with unbalance weight such as crankshaft, its
main spindle system cannot operate in the desired constant rotating speed, because unbalance
torque usually arises in the work piece. In order to keep constant operation speed against the
gravitational unbalance torque, usually control motor is adopted in the spindle system with
geared transmission in addition to main driving motor. However, the static pre-torque
produced by the control motor is half the unbalance torque, so it may compensate at most
half the unbalance torque of the work piece. The resulting rotating speed variations in the
main spindle or work piece may cause undesirable or bad effects on machining accuracy

Fig6. Schematic diagram of turret lathe

spindle
Ø Vibration Monitoring - This is the most commonly used and effective technique to detect
internal defects in rotating machinery.
Ø Acoustic Emission Monitoring - This involves detection and location of cracks in bearings,
structures, pressure vessels & pipelines.
Ø Oil Analysis - Lubrication oil is analyses and the occurrence of certain microscopic particles
in it can be connected to the conditions of bearings & gears.
Ø Particle Analysis - Worn machinery components, whether in reciprocating machinery,
gearboxes or hydraulic systems, release debris collection analysis of this debris provides vital
information on the deterioration of these components.
Ø Ultrasonic Monitoring - This is used to measure thickness of corrosion or crack on
pipelines, offshore structures, and pressure vessels.
Ø Thermography - This is used to detect thermal or mechanical defects in generators,
overhead lines, boilers, misaligned coupling and cell damage in carbon fibre structures on
aircrafts.
Mounting Methods of vibration Sensors:
The mounting of a vibration sensor (accelerometer) directly impacts on its performance.
Incorrect mounting may give readings that relate not only to a change in conditions but also to
the instability of the sensor itself – therefore making the sensor’s readings unreliable. As such,
correct mounting of a vibration sensor is vital to ensure true readings.

However, despite the importance of getting vibration sensor installation right, poor mounting is a
surprisingly common practice, much to the detriment of manufacturers.

The mounting process doesn’t need to be complicated. The following brief vibration monitoring
mounting guidelines below, describe where and how to mount your accelerometers correctly.

To detect any faults in machine components, vibration sensors should be mounted in locations
that ensure horizontal, vertical and axial movement are measured effectively:

1. For horizontal measurement, vibration sensors should be mounted on the motor bearings
and pump bearings. This measures velocity mm/sec (Peak or RMS) to detect unbalance,
and problems with structural rigidity and/or foundation.
2. For vertical measurement, sensors should be located on the motor and pump drive end
bearings. This measures velocity mm/sec (Peak or RMS) to detect looseness and
problems with structural rigidity and/or foundation.
3. For axial measurement, sensors should be attached to the motor and pump drive end
bearings. This measures velocity mm/sec (Peak or RMS) to detect misalignment between
the motor and the fan.

Accelerometers should be mounted onto a surface that is free from oil and grease as close as
possible to the source of vibration. The surface should be smooth, unpainted, flat and larger than
the base of the accelerometer itself. For best results, sensors should be mounted via a drilled and
tapped hole directly to the machine housing.

Fig 7. Sensor mounted on turret Lathe

Ø Graphs of the vibration patterns on turret Lathe

Vibrational analysis of spindle of a turret lathe was made in case 1 and the same vibrational
Analysis of the spindle was made with an unbalanced work piece in case 2 on a turret Lathe.
Both the trends were projected and compared as shown.

We concluded from the vibrational Analysis that

1. The spindle system of a lathe with unbalanced work piece cannot operate in the desired
constant rotating speed as far as the gravitational unbalance torque is engaged.
2. The pure torsional velocity amplitude of the spindle increases infinitely near the spindle
speed corresponding to the system resonant frequencies, so the spindle system cannot
operate normally with these speeds.
3. The pure torsional vibrations of the spindle cannot be neglected during other spindle
speed ranges, so it may cause bad effects on machining accuracy.