DATA DRIVEN-BASED RUL ANALYSIS FOR THE

EFFECT OF THE CRACK GROWTH WITHIN

MECHANICAL COMPONENT ON PROCESS
PERFORMANCE & QUALITY
Eng./ AHMED M. GOUDA

Supervision:
Prof./ YASSER SHABAN
Dr./ RAMY M. KHALIFA
CONTENTS

• Crack Initiation and Growth Process

• Factors Affecting The Rate Of Crack Growth
• Crack Growth Detection
• Crack Growth Consequences On Process Performance
• What Is The Rul And How It A Useful Indication For The Operation?
• Modeling RUL of a cracked Component using Advanced Techniques
• What Is Digital Twins (Dt) And How It Can Be Applied?
• Research Objectives

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 CRACK INITIATION AND CRACK GROWTH
PROCESS

• Cracks are a critical issue in any mechanical

system.
• Crack size increasing with increasing of number of
cycles of applied load.
• Rate of crack growth starts in low rate and then
increasing gradually with increasing of crack size.

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 Crack growth rate on the y-axis and range on intensity factor on the x-axis

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FACTORS AFFECTING THE RATE OF CRACK
GROWTH
The rate of crack growth through a
material depends on several factors:

• Cyclically applied loads (magnitude

and direction)
• Material nature
• Ambient conditions
• poor installations (which may lead
to overheating and excessive
vibrations which may increase crack
growth rate.
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Effect of applied stress on the crack length and cycles to failure Effect of temperature on the crack length and cycles to failure

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CRACK GROWTH CONSEQUENCES ON
PROCESS PERFORMANCE
• Crack growth within the any component has a critical effect on the
its performance and its ability to do a specific task
• Its expected from any component to do its specific task without any interruption
leading to degradation in process performance or the final product acceptable
quality
• Crack growing within component affect not only on component but also on the
processes depend on that component and also on the quality of final product.
• The crack growth affects the natural frequency of component it growing within its
structure, which leads to variations in the features of the vibration signals.
• Crack growth reduces the overall stiffness of the component and increase its
flexibility.

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CRACK GROWTH DETECTION

 Traditional Methods
1. Regular Visual Inspection on Components:
" with the naked eye or using optical gadgets(e.g. magnifying
glasses, microscopes, or endoscopes)."

• In expensive
• Low accuracy
• No on time state of the component
• Crack may occur and grow between two scheduled inspections
• Need high level of experince to specify level of cracks
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CRACK GROWTH DETECTION

• Traditional Methods
2. Crack testing with dye penetrant testing (PT)

• In expensive
• Low accuracy
• No on time state of the component
• Crack may occur and grow between two scheduled
inspections

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CRACK GROWTH DETECTION

 Sensors Techniques
1. Discrete strain sensors
Direct
2. Distributed strain sensors
Contact
3. Magnetic Particle Testing
4. Vibro – Thermography Indirect
5. Wave monitoring sensors Contact

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 CRACK GROWTH
DETECTION

 Discrete Strain Sensors

- This type of sensors depends on strain variety
which is a parameter directly correlated to stress.

- Strain change in structure due to crack would be

transmitted sensor

- Then can be collaborated to any reading unit.

- More length more sensitivity

Ex.

- Strain gages

- Long gage fiber optic

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 CRACK GROWTH
DETECTION

 Distributed Strain Sensors

- Distributed sensor can replace
many discrete sensors

Ex.
- Eddy current sensor

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 CRACK GROWTH
DETECTION

• Magnetic Particle Testing

- detect cracks at the surface of

ferromagnetic materials
- magnetisation of the component

- surface coated with small magnetic particles

- Surface cracks create a flux leakage field in

the magnetised component
- magnetic particles are attracted to the flux
leakage and thereby cluster at the crack

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CRACK GROWTH
DETECTION

 Vibro – Thermography

• ultrasonic frequencies to excite

the specimen.
• friction between vibrating cracks
• heat signatures
• surface map identifying localized
hotspots.

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 CRACK GROWTH
DETECTION

 Wave Monitoring sensors

- Distributed sensor can
replace many discrete
sensors

Ex.
- Vibrations wave
- Acoustics waves

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 Crack detection in a rotating shaft using artificial neural networks and PSD characterization, A. A. Mohammed, R. D.
Neilson, W. F. Deans. P. McConnell

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 Macro T. C. Faria, Gilberto Luiz S., “ACOUSTIC EMISSION TESTS ON THE ANALYSIS OF CRACKED SHAFTS OF
DIFFERENT CRACK DEPTHS “, 2015, Research Gate.

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REMAINING USEFUL LIFE (RUL)

 Increasing of Crack growth limits the

life time of the rotor component.
 RUL refers to remaining useful life,
it is an indicator of the remaining
period of time of the component
under study at which it can give an
output we expect it to give without
any errors or interruptions. So RUL
can also say “It’s the time between
the system’s current state and its
failure state”.

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REMAINING USEFUL LIFE (RUL)

- There are several ways to estimate RUL depending on the data we have:

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REMAINING USEFUL LIFE (RUL)

 RUL of the process is not means only breakdown failure.

 A desired quality of a product may be the indicator of RUL for our component.
 Crack growth within material have an impact on the component performance
which will have a direct impact on process and product quality.
 To find the RUL approach for our component we need a time series of data which
will be analyzed using data driven model approach.

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MODELING RUL OF A CRACKED COMPONENT
USING MACHINE LEANING TECHNIQUES

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 WHAT IS DIGITAL TWINS (DT)?

 Things do not stop on

collecting actual data. We
need to simulate one, for
future scenarios simulation.

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PROBLEM STATEMENT

 The crack within the material of the rotating part in addition to its being
considered a main reason for failure in the last stages of the crack growth process.
 This crack growth has a noticeable effect on the performance of the process
which in turn affects the quality of the process and products.
 The major challenge is to determine the appropriate time for replacement of the
defected rotor component based on quality of the process and products.
 Therefore, the meaning of RUL gets different as it is based on the process
performance.

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RESEARCH OBJECTIVES: PROPOSED APPROACH

Quality Variables

Vibration Signal MACHINE PREDICTIVE

PROCESS DATA
LEARNING MAINTENANCE
COLLECTION
MODEL PLAN

RUL ESTIMATION

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RESEARCH OBJECTIVES

 Develop a driven machine learning model to determine the relationship between

crack depth within the rotor component and the quality parameters of the process
and product.
 Maintain the RUL threshold of the rotor component based desired quality of
industrial application.
 Build a physical model to simulate the cracked shaft to make virtual scenarios and
create simulated data to use for future problem forecasting (DT).

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BENEFIT OF RESEARCH

 Collecting and analysis a vibrations or any data can give good insights we can use
to know the remaining useful life for our component "according the growthless of
crack within it” after which it will have a non-acceptable process performance or
product quality.
 This will reducing a downtime and catastrophic failure consequences
 Ensuring that the products will be produced will be with acceptable quality
specifications.

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REFERENCES

 1. Menegon, J. and E.L. Isatto, Digital twins as enablers of structure inspection and
maintenance. Gestão & Produção, 2023. 30.
 2. Pejić Bach, M., et al., Predictive Maintenance in Industry 4.0 for the SMEs: A Decision
Support System Case Study Using Open-Source Software. Designs, 2023. 7(4): p. 98.
 3. Utz, S., et al., Mechanism of crack initiation and crack growth under thermal and
mechanical fatigue loading. 2013.
 4. Bejaoui, I., D. Bruneo, and M.G. Xibilia, Remaining useful life prediction of broken rotor
bar based on data-driven and degradation model. Applied Sciences, 2021. 11(16): p. 7175.
 5. Mohammed, A., et al., Crack detection in a rotating shaft using artificial neural networks
and PSD characterisation. Meccanica, 2014. 49: p. 255-266.
 6. Dimarogonas, A.D., Vibration of cracked structures: a state of the art review. Engineering
fracture mechanics, 1996. 55(5): p. 831-857.
 7. Swanson, L., Linking maintenance strategies to performance. International journal of
production economics, 2001. 70(3): p. 237-244.

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 THANK YOU

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