LAB 1

FAKULTI TEKNOLOGI KEJURUTERAAN

MEKANIKAL DAN PEMBUATAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BMMM 3543 DIAGNOSTIK DAN PENGENALPASTIAN MASALAH PENYELENGGARAN

LAB SHEET 1

SHAFT CRACK

Learning LO2 Display the methods of monitoring diagnostics data processing using
Outcome (LO):
methods of data analysis and diagnostics
Program PO5 Ability to select and apply appropriate techniques, resources and
Outcome:
modern engineering tools, with an understanding of their limitations.
Synopsis: Students will be exposed to basic diagnostics techniques and methods used in
identifying the failure of the machinery system. Fault tree analysis method is
important for the purpose of monitoring data for maintenance of a machine system
as well. This course will also discuss the diagnostics data processing and
distribution of statistical diagnostics for smooth management of maintenance work.
Related Lecture’s 1. Vibration as machinery diagnostic tool
Topic:
2. Machinery failure Analysis

Prepared by: TS. DR. NOR AZAZI BIN NGATIMAN Date: 1 October 2021
Approved by DR. MUHAMMAD ILMAN HAKIMI CHUA BIN
Date
LM/SLM/HOD ABDULLAH

QMS : REVISION RECORDS

Revision Date Approved by

Description Prepared by :
No (DD/MM/YY) LM/SLM/HOD:
1.0 THEORY

A shaft crack at the protruding end of the shaft is to be simulated. The simulation will be carried out
using the short shaft with flange. The constant radial load is created using the belt drive. The frequency
spectra for the three experiments are to be compared. The experiment will perform a shaft with a
simulated crack. Cracks caused by material fatigue are very dangerous for rotating machines as they
often lead to the dreaded fatigue fracture with fatal consequences. Therefore, early detection is vital
step. A crack in the shaft influences the shaft’s vibration behaviour by changing its rigidity. These
changes can be identified by measuring the vibrations on the shaft and using appropriate analysis
software.

Objectives
At the end of this laboratory session, students should be able to:
a) Identify cracks n from the change in vibration spectrum
b) Detect cracks in rotating shafts at a protruding shaft end and in a shaft with an elastic rotor
c) Use computerised vibration analyser.
d) Understand and interpret frequency spectra

2.0 EQUIPMENTS/ EXPERIMENT APPARATUS/ CONSUMABLE MATERIALS

This unit simulates the characteristic behaviour of a shaft with a crack using an asymmetrical flange
connection (Figure 2.1 – Figure 2.3). Overall layout of the equipment is shown in Figure 2.4. The flange
connection is provided by six screws distributed around the circumference. Tightening the flange
connection with spacer sleeves gives a connection that is either loose or secure depending on the
installation direction of the spacer sleeves. When rotated with a bending load, this flange connection
results in intermittent separation of the butt joint. This very closely resembles the behaviour of a crack
in the shaft. To create this behaviour, it is necessary to load the flange connection with a bending
torque (e.g. using the PT 500.14 belt drive or an imbalance from a weight).

Fig 2.1 : Shaft with no crack – Fig 2.2 : Shaft with small crack – Fig 2.3 : Shaft with maximum crack
Flange connection with Flange connection with – Flange connection with
six supporting screws five supporting screws two supporting screws

A = Loose connection B = Secure connection

2.1 Assembly of the flange connection for simulation of a crack

Align the flange with the shaft as shown in Fig. 2.4 (7 or 8) and pick up disc (4) using the centring pin
(3) and secure with the hexagon head screws (5).
 1. Driving shaft (PT 500) 5. Hexagon head screws
2. Clamping set 6. Spacer sleeve
3. Centring pin 7. Fange with long shaft (output weight)
4. Pick up disc 8. Flange with short shaft (output for belt drive)

Fig 2.4 PT 500.11 – Crack Detection in Rotating Shaft Kit

Fig 2.5 : Loose connection Fig 2.6 : Secure connection

with spacer sleeve with spacer sleeve

It is important to understand; the discs cannot be centred using the screws alone. Depending on the
function, insert and tighten the spacer sleeves (6). The use of a spacer sleeve for a loose connection
can be seen in Fig. 2.5. In this type of connection, the flange and pick up disc are held together by the
screws with clearance. When using the spacer sleeve for a secure connection, turn the spacer sleeve.
The use of a spacer sleeve for a secure connection can be seen in Fig. 2.6. In this type of connection,
the flange and pick up disc are held together by the screws force with no clearance. Insert the shaft
clamping set (2) in the pickup disc (4). Fit the “shaft with crack” in the experimental setup on one end
of the short shaft using the shaft clamping set.

NOTICE
• At least two screws in the flange connection must be securely tightened to give a secure
connection with no clearance. For safety and to prevent imbalances, all screws must always
be fitted.

• At least two of the six hexagon head screws distributed around the circumference must be
securely tightened with no clearance with spacer sleeves.
3.0 PROCEDURES/ METHODOLOGY

Fig 3.1 Schematic diagram above testing apparatus

1. The simulation of “crack in shaft” with protruding shaft end experiment can be performed as
set up illustrate in Fig 3.1.
2. Prepare the “shaft without crack” for the experimental process, i.e. fit all six screws with spacer
sleeves as a secure connection.
3. The flange should be fitted as described below.
i. Simulation of shaft without crack
• Six hexagon head screws with
spacer sleeves installed as a
secure connection (Fig.3.2).
ii. Shaft with crack
• Four hexagon head screws with
spacer sleeves as a loose
connection (Fig. 2.5).
• Two hexagon head screws with
spacer sleeves as a secure
connection (Fig.2.6) Fig. 3.2 : Pick up disc with clamping set, short shaft
with flange and small belt pulley. Two
supporting screws (A)
4. Secure the small belt pulley (3) to the end of the short shaft with flange using the clamping set.

i. Assemble the belt drive with the

bearing block and belt tensioner from
the PT 500.14 (belt drive), align and
slightly tension the belt.

ii. The correct direction of rotation must

be ensured. The belt tensioner must
be fitted on the unloaded side of the
belt. The belt tension (Fig. 3.3) can be
adjusted using the belt tensioner. For
each belt drive, the adjusting screw
moves a tension roller into the loose
side of the belt from below until the Fig. 3.3 : Belt tension adjusted using feeler or
alternatively with belt pretension measuring
belt is slightly tensioned.
unit (tension approx.. 70 N)

iii. Adjust the belt tension for the shaft

with crack. The belt tension should be
increased until the feeler fits 0.4 mm
into the gap between the flange on
the side opposite the supporting
screws. A measurement should also
be carried out on the side opposite
the belt drive (on the side where
tensile stress is acting on the shaft). Fig. 3.4 : Belt drive with tensioner

iv. Alternatively, the tensile stress of the

belt can be measured using the belt
pretension measuring unit (Fig. 3.5).

Fig. 3.5 : Belt pretension measuring unit

5. Check the switching behaviour of the reference sensor. The second LED directly on the
reference sensor may only trip once when scanning the reflective mark.

6. In the software, open the “Sensor” window.

• Select the sensor and check the settings in
• the “Calibration” menu.
• Sensor: Acceleration o Scale: 100 mV/g
• Offset: 0.0
• Factor: 1.0
• Gain on measuring amplifier: 10x.
7. In the software, open the “Frequency Spectrum” window and check the following settings.
• Channel A: Channel 1
• Channel B: Reference
• Scan Rate: 8 k/s
• Scan Time: 4 Seconds
• Of Means: 1
• Mode: Velocity
• Window Function: Uniform
• Log Or Linear: Linear
• Unit Of Magnitude: rms
8. Recording the frequency spectrum
• Recheck that all parts are fitted securely.
• Close the protective hood.
• Switch on the control unit for the motor.
• Set the direction of rotation (determined by the belt drive - the belt tensioner should act on the loose
side).
• Set the speed to zero.
• Switch on the motor.
• Set the speed (1200 -1800 rpm)
• Plot the frequency spectrum.
• Set the speed to zero.
• Switch off the motor.

9. Prepare the “shaft with small crack” for the experimental process, i.e. fit five adjacent screws with
spacer sleeves as a secure connection and the other three as a loose connection. Repeat step 6
– 7 above

10. Prepare the “shaft with crack” for the experimental process, i.e. fit two adjacent screws with spacer
sleeves as a secure connection and the other four as a loose connection. Repeat step 6 – 7 above

Note: To show the difference in the comparison, the “shaft without crack” is recorded first.

4.0 RESULTS
Print the graph from vibration analyser software

5.0 DISCUSSION
Write your discussions about this experiment.

6.0 CONCLUSION
Give conclusion and summarize the main findings of this laboratory work.

7.0 QUESTION
Group 1&6: Explain waveform and spectrum changes from the normal and faults condition.
Group 2&7: Explain the application of shaft in real industry.
Group 3&8: Explain analysis techniques that has been done by previous researhers.
Group 4&9: Explain about other shaft faults.
Group 5&10: Explain safety procedure for this experiment activity.

8.0 OTHERS
List at least three references.
ASSESSMENT CRITERIA:

Your response to each task will be graded separately based on the checklist attached. To obtain
maximum marks, ensure that your response addresses each of the tasks in the question accordingly.

Assessment checklist for Lab Activity 1

Mark
Assessment tasks LO PO C/P/A level SK SP TA
allocation

Procedure (Ability to
P1 -
describe experiment 10 LO2 PO5 Perception
with correct procedure)

Work Process (Ability

to explain experiment 10 LO2 PO5 P2 - Set
faults)

Work Process (Ability

P4 –
to display data – 15 LO2 PO5 Mechanism
Fotography skills)

Outcome (Analysis P4 –
25 LO2 PO5 SK6 SP1,SP3
results) Mechanism

P5 - Complex
Outcome (Explanation
15 LO2 PO5 Overt SK6 SP1,SP3
of the results) Response

P5 - Complex
Outcome (Discussion
15 LO2 PO5 Overt SK6 SP1,SP3
and conclusion) Response

Discipline (On time

submission with no 10 LO2 PO5 P2 - Set
plagiarism)

TOTAL 100

SPECIFIC INSTRUCTION

1. Answer in ENGLISH .
2. Must include list of references .
3. Submit your assignment ONCE only in a SINGLE file.
4. Submit your assignment ONLINE.
5. Submission date: Refer U-learn
6. This lab report/activity accounts for 5% of the total marks for the course.
APPENDIX
 LAB 1
FAKULTI TEKNOLOGI KEJURUTERAAN
MEKANIKAL DAN PEMBUATAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
DIAGNOSTIK DAN PENGENALPASTIAN MASALAH
BMMM 3543
PENYELENGGARAN

LAB REPORT 1

SHAFT CRACK

TS. DR. NOR AZAZI BIN NGATIMAN

INSTRUCTOR’S NAME
HAMZAH BIN MOHD DOM

STUDENT’S PHOTO STUDENT’S NAME MATRIX NO:

S1.

S2.

S3.

S4.

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: …………………………………………….........
 LAB REPORT RUBRIC
Very Weak Weak Modest Good Excellent
Item Description Weightage Marks
1 2 3 4 5
Procedure (Ability
Unable to identify and Able to identify but No mistakes while Students are
to describe Minor mistakes while
1. mishandling the unable to use using equipment, but comfortable with the 10
experiment with using equipment
equipment equipment not comfortable equipment
correct procedure)
Work Process Most of the work Work process are
Work process is Major work process Some work process
2. (Ability to explain process are followed followed correctly 10
missing or unclear are missing are missing
experiment faults) correctly and in order
Work Process
Most data are All data are taken but
(Ability to display All data are missing Most data are All data are correctly
3. correctly taken, no minor data are 15
data – Fotography or incorrect missing or incorrect taken
missing data incorrect
skills)
Trends/patterns are Trends/patterns are
Trends/patterns are
Trends/patterns are Trends/patterns are logically analyzed for logically analyzed
logically analyzed
not analyzed not analyzed the most part
Outcome (Analysis Questions are
4. Questions are 25
results) Questions are not Answers to questions Questions are answered thoroughly
answered in
answered are incomplete answered in and in complete
complete sentences
complete sentences sentences

Analysis is Analysis is insightful

Analysis is not Analysis is general Analysis is thoughtful
inconsistent Their effect and ways
relevant comparison Their effects are
Outcome Most of the results
Some of the results to reduce errors are
5. (Explanation of the of data indicating a discussed 15
have been correctly
results) have been correctly discussed
lack of understanding
interpreted and Almost all of the
of results interpreted and All-important trends
discussed, only minor results have been
discussed; partial but and data
 incomplete improvements are correctly interpreted comparisons have
understanding of needed. and discussed. been interpreted
results is still evident correctly and
discussed, good
understanding of
results is conveyed

Unrelated Poorly conducted Moderately Good quality Excellent quality

discussion and discussion and conducted discussion discussion and discussion and
conclusion on the conclusion on the and conclusion on conclusion on the conclusion on the
Outcome
6. (Discussion and criteria that will criteria that will the criteria that will criteria that will criteria that will 15
conclusion) indicate the project indicate the project indicate the project indicate the project indicate the project
objectives have been objectives have been objectives have been objectives have been objectives have been
met. met. met met. met.

Documentation
Documentation is the
follows designated
Paper lacks many appropriate length as
Paper follows most guidelines. Paper is
Discipline (On time elements of correct Paper follows most described for the
7. submission with no guidelines but the appropriate 10
formatting. Paper is guidelines. assignment. Format
plagiarism) inadequate in length. length as described
inadequate in length. enhances readability
for the assignment.
of paper.
Format is good.

/100