LAB 1

FAKULTI TEKNOLOGI KEJURUTERAAN

MEKANIKAL DAN PEMBUATAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BMMM 3043 MECHANICAL VIBRATION

LAB REPORT 1

VIBRATION MONITORING - GEAR

TS. DR. NOR AZAZI BIN NGATIMAN

INSTRUCTOR’S NAME
TS. DR. MOHD IRMAN BIN RAMLI

STUDENT’S NAME MATRIX NO:

S1. KARTHIGESAN A/L DURAISAMY B091910075
S2. KEEVANISH A/L SURESH CHANDRA B091910100
S3. MUHAMMAD AMMAR IZZAT BIN ABD RAZAK B091910281
S4. MOHAMAD AMIR BIN IBRAHIM B091910207
S5.

ASSESSEMENT RUBRICS
MARK
ASSESSMENT TASK/ITEMS GIVEN MARKS
ALLOCATION
1. Procedure (Ability to describe 10
experiment with correct procedure)
2. Work Process (Ability to explain 10
experiment faults)
3. Work Process (Ability to display data – 15
Fotography skills)
4. Outcome (Analysis results) 25
5. Outcome (Explanation of the results) 15
6. Outcome (Discussion and conclusion) 15
7. Discipline (On time submission with no 10
plagiarism)
TOTAL MARKS 100

Approved By: ………………………………………………..…..

(Instructor’s Signature & Stamp)

Date: …………………………………………….........
PROCEDURE & WORK PROCESS
A. EXPERIMENTAL PROCEDURE

General Setup :
 Speed fD: 1200rpm
 Number of teeth on small wheel: 25
 Number of teeth on large wheel:75
 Engagement frequency (Gear mesh) fz: number of teeth x running speed fz: 25 x 20 = 500 Hz

B. CHANGING THE GEAR AND RUNNING THE SOFTWARE

1. There are two gear The mark F gear is defect gear and the other gear is normal gear that is not
defect.
2. The coupling screw was loosened.

3. The part was shifted to make space to remove the shaft and change gear

4. All the nut and screw outside and inside of the box was loosened to change the gear

5. The gear was installed and must installed properly to avoid gear teeth damage when it slip.
6. The position of big and small gear was alligned when installed. It can caused gear teeth damage if
not install properly when it slip.

7. After all the part was fitted securely, the protective hood was closed .

8. Before switch on the control unit for the motor, the sensor must show bip 2 times and was
checked to make sure it function properly. Sensor that is not in right position will not detect the
vibration.

9. The desired direction of rotation was set.

10. The speed was set to zero

11. The motor was switch on and the speed was set to 1300 rpm and 2100 rpm.

12. After the motor reached 1300 rpm the brake is on and the result was taken

13. After the result is taken the brake was off.then the speed was raise to 2100 rpm

14. The brake & load unit was switch off or set the load to zero.
15. The frequency spectrum was recorded using the PT 500.04 software. The “velocity” parameter for
the y axis in the “Mode” drop-down list was set

16. All the data was recorded

C. REPEAT THE PROCEDURE WITH FAULTY GEAR.

D. SAVE THE FREQUENCY SPECTRUM AND MAKE A COMPARISON ANALYSIS.

 RESULTS AND ANALYSIS
Normal gear at 1300rpm

figure 1: low speed with no brake load

Figure 2: low speed with brake load

Based on the spectrum, the highest vibration occurs at 49.2hz for both conditions with the
value of 0.3374mm/s. the lowest vibration occurs at 196.5hz for figure 1, at 74.0hz for figure
2. The graph shows that at the starting of the gear moving, this velocity suddenly spike to its
maximum value and as time follows the velocity gradually decreased.
Normal gear at 2100rpm

Figure 3: high speed with no brake load

Figure 4: high speed with brake load

The maximum velocity and frequency that has been reached for figure 3 are 0.3394 mm/s
and 49.2hz. for figure 4, the graph shows the maximum velocity and frequency are 0.3661
mm/s and 49.2hz. Based on the graph, the longer the gears move the less the velocity are.
 Defect gear at 1300rpm

Figure 5: low speed with no brake load

Figure 6: low speed with brake load

Based on the spectrum, the highest vibration occurs for figure 5 at 5.2hz and the velocity
value is 0.7345 mm/s. The lowest vibration occurs at 85.5hz for figure 1, at 149.5hz for
figure 6. The graph shows that at the starting of the gear moving, this velocity suddenly
spikes to its maximum value and as time follows the velocity gradually decreased.
Defect gear at 2100rpm

Figure 7: high speed with no brake load

Figure 8: high speed with brake load

For figure 7, the maximum velocity reached is 0.3664 mm/s with a frequency 7.0hz. Then,
the minimum vibration occurs at 28.0hz with a velocity 0.0816 mm/s. At figure 8, the graph
shows fluctuation occurs at the beginning. The maximum velocity and frequency for figure 8
are 0.1696 mm/s and 6.8hz .
 DISCUSSION AND CONCLUSION

Vibration monitoring is described in this experiment as the continuous monitoring of rotating equipment
such as gears, pumps, and compressors using a set of tools to detect the state of the equipment that can generate
vibration in the system. One of the gadget systems used in this lab job is Gear. A gear is a circular rotating
machine part with cut teeth or a cogwheel that transmits torque by meshing with another toothed element. The
gear transmission system has been widely employed in all technical applications. In the automotive and heavy
industrial industries, gear transmission boxes are most typically used to control shaft speed. In a gear
transmission or train, there are two fundamental types of spur gears. There are a few flaws in the experiment,
such as gear looseness. The gear assembly should be tight and tidy so that it does not slip when running, which
could harm the gear teeth. Aside from that, this experiment can detect misalignment of the gear. A hoop on the
coupling caused by misalignment of the gear might lead to false readings. Next, one of the experiment flaws
detected in this experiment is the sensor not being in the proper position. As a result, the vibration will be missed
by the sensor.

The gear transmission system has been widely employed in all technical applications. In car engineering,
gear is used to transfer torque from an internal combustion engine to the wheels. In the heavy machinery
business, gear transmission boxes are often employed to control shaft speed. As a result, keeping track of gear
performance is vital in order to achieve optimal overall system performance. One of the most easy techniques is
vibration monitoring and analysis. In this experiment, the vibration of many sets of gear is recorded and
investigated.

As a result, keeping track of gear performance is vital in order to get the best overall system performance.
There are two sorts of vibration that can be used: vibration monitoring and vibration analysis. Early diagnosis of
equipment damage or failure is aided by vibration monitoring systems, preventing catastrophic consequences
such as equipment failure and life expectancy exceeding estimates. In other words, if we check the state of the
gear machine on a regular basis, we will be able to see any problems that may emerge while it is in use.

Furthermore, if machine vibration is not detected early enough, it can cause major machine damage, forcing
costly repairs and gear replacement. As a result, by routinely inspecting the quality of the gear parts, possible
faults can be identified early on, resulting in cheaper maintenance costs and easier maintenance. As a result, it
will be able to save money on new machine parts as well as maintenance.

CONCLUSION

As a result, the gear transmission mechanism can be investigated. The driver and driven gear have been set up
using normal and fault gear. The vibrations of the gears can then be monitored while the machine is running to
detect whether there is any fault. As a result, the analysis graph shows that when the graph reaches a peak, some
difficulties have been discovered. Following the defect diagnostic technique for gears, we can determine and
know how to use a vibration analysis machine with variable rpm but the same torque
QUESTION ANSWER
Suggest the solution to reduce the vibration generated

When gears work, especially at high loads and speeds, the noise and vibration caused by the
rotation of the gears is considered a big problem. However, since noise problems tend to
happen due to several causes in combination, it is very difficult to identify the cause. The
following are ways to reduce vibration points should be considered in the design stage of
gear systems.
1. Use High-Precision Gears
Reduce the pitch error, tooth profile error, runout error and lead error. Grind teeth to
improve the accuracy as well as the surface finish.
2. Use a Better Surface Finish on Gears
Grinding, lapping and honing the tooth surface, or running in gears in oil for a period
of time can also improve the smoothness of tooth surface and reduce the vibration.
3. Ensure a Correct Tooth Contact
Crowning and end relief can prevent edge contact. Proper tooth profile modification
is also effective. Eliminate impact on tooth surface.
4. Have a Proper Amount of Backlash
A smaller backlash will help produce a pulsating transmission. A bigger backlash, in
general, causes less problems.
5. Increase the Transverse Contact Ratio
A bigger contact ratio lowers the noise. Decreasing the pressure angle and/or
increasing the tooth depth can produce a larger contact ratio.
6. Increase the Overlap Ratio
Enlarging the overlap ratio will reduce the vibration. Because of this relationship, a
helical gear is quieter than the spur gear and a spiral bevel gear is quieter than the
straight bevel gear.
7. Eliminate Interference on the Tooth Profile
Chamfer the corner of the top land, or modify the tooth profile for smooth meshing.
Smooth meshing without interfering makes less vibration.
8. Use Gears that have Smaller Teeth
Adopt gears with a smaller module and a larger number of gear teeth.
9. Use High-Rigidity Gears
Increasing facewidth can give a higher rigidity that will help in reducing vibration.
Reinforce housing and shafts to increase rigidity.
10. Use Resin Materials
Plastic gears will be quiet in light load and low speed operation. Care should be taken
to decrease backlash, caused from enlargement by absorption at elevated
temperatures.