VIBRATIONAL ANALYSIS

OF A FAULT BEARING
 Scope of project
 Rolling element bearings are widely used in rotating
machinery across various industries that include aerospace,
construction, mining, and railways. The damage and failure
of bearings contribute to machinery breakdown,
consequently causing significant economic losses and even
loss of human lives in certain situations, such as train
derailment due to seizure of a bearing. Undesirable
vibrations in rolling element bearings can be caused by
faulty installation, localised defects or distributed defects .
While the distributed defects are associated with
manufacturing imperfections, such as roughness, waviness,
off-sized components, and misaligned races, the localised
defects are caused by surface contact fatigue.
 In a properly installed and lubricated bearing, the onset
of micro-scale subsurface fatigue cracks commences
below the rolling surfaces that continue to progress
towards the surface during the operation of a bearing,
eventually causing the material to break loose or flake
off, leading to the formation of macro-scale surface
spalls or pits. It is well known that whenever a
defective component, a rolling element, outer raceway
or inner raceway, within a bearing interacts with its
corresponding mating components, abrupt changes in
the contact stresses occur. These changes structurally
excite the bearing resulting in the generation of
vibrations, and consequently, acoustic signals which
can be monitored to detect the presence of a defect
using appropriate condition-based (vibration and
acoustic) diagnostic techniques.
 CNC WIRE CUT MACHINE:

 The wire-cut type of machine arose in the 1960s for the purpose of making
tools from hardened steel. The tool electrode in wire EDM is simply a wire. To
avoid the erosion of material from the wire causing it to break, the wire is
wound between two spools so that the active part of the wire is constantly
changing. The earliest numerical controlled (NC) machines were conversions
of punched-tape vertical milling machines. The first commercially available
NC machine built as a wire-cut EDM machine was manufactured in the USSR
in 1967. Machines that could optically follow lines on a master drawing were
developed by David H. Dulebohn's group in the 1960s at Andrew Engineering
Company for milling and grinding machines. Master drawings were later
produced by computer numerical controlled (CNC) plotters for greater
accuracy. A wire-cut EDM machine using the CNC drawing plotter and optical
line follower techniques was produced in 1974. Dulebohn later used the same
plotter CNC program to directly control the EDM machine, and the first CNC
EDM machine was produced in 1976.
 Laser Doppler vibrometer

 A laser Doppler vibrometer (LDV) is a scientific instrument

that is used to make non-contact vibration measurements of a
surface. The laser beam from the LDV is directed at the
surface of interest, and the vibration amplitude and
frequency are extracted from the Doppler shift of the
reflected laser beam frequency due to the motion of the
surface. The output of an LDV is generally a continuous
analog voltage that is directly proportional to the target
velocity component along the direction of the laser beam.
 TEST RIG
 Description:  Diagram of rig
A.) Elements:
 Motor

 coupling
 Shaft

 Bearing carriers

 2 bearing sets:

Normal bearings and

faulted bearings.
 Silver strips
B.)Construction:
 A small shaft comes from the motor running at high
speeds.This is coupled with the main shaft using an
oldham coupling.
 The main shaft runs through 2 bearing carriers which are
fixed to the base of the test rig.
 A normal faultless bearing is fixed into the carrier nearer
to the motor.
 The faulted bearings are fixed into the carrier on the
farther end of the shaft.
 The 2 discs are keyed to the shaft.
 We attach silver strips to both the bearing carriers.
C.)Procedure:
 After completely fixing the
equipment, the test rig is placed
in such a way that the strips are
exactly perpendicular to the
laser vibrometer put in it’s front.
 This is confirmed by looking at
the reading on laser equipment.
 Vibrational analysis graphs for
the following speeds are
obtained:
a.)500 rpm c.)1500 rpm e.)2500 rpm
b.)1000rpm d.)2000 rpm f.)3000 rpm
Test Rig
500rpm 1000rpm
1500rpm 2000rpm
2500rpm 3000rpm
 Conclusion
 It is observed that fault on ball produce the
least harmonics
 Fault on inner race and outer race produce
noticable harmonic frequencies.
 The frequencies are too high if there are
multiple faults.
THANK YOU