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STATISTICAL ANALYSIS AND OPTIMIZATION OF DIFFERENT PROCESS

PARAMETERS AFFECTING BEARING VIBRATION


A
Presentation
submitted
in partial fulfillment
for the award of the Degree of
Master of Technology
in Department of Mechanical Engineering
(With specialization in Production Engineering)

Guided by – Dr. Alok Khatri (Assistant Professor) Submitted by – Parth Vyas


(Engineering College Ajmer) Roll Number – 15EEAPE605

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OUTLINES

• Introduction
• Literature review
• Research gap
• Objective
• Experimental setup
• Research Methodology
• Design of experiment
• Particle Swarm Optimization
• Experimental results
• Conclusion
• Future scope
• References

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INTRODUCTION

Bearing plays a very important role in any machine. Without bearing, it is very difficult for a rotary element to
rotate during any machining operation. It helps in load transmission and not only that, it also reduces the friction
which in turn reduces the power and effort required during the operation.

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Hydrodynamic bearings

Classification of Bearing Hydrostatic bearings

Rolling element bearings


Bearing

Defects in Bearing

Lubrication failure

Contamination

Improper Mounting

Overheating

Corrosion

Misalignment and Mass Unbalance

False Brinelling

Fatigue
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LITERATURE REVIEW

• Gupta et al. (Year 1997) The Vibration analysis deals with the extraction of the feature from a signal which
can give results and analyses whether the components of a machine are good or not. In real all the
components of machine produce vibration. Under normal condition, when the bearing is in operation and is in
healthy state, level of the vibrations are very small and stable; but, when the defects arises, some of the
process related to machine dynamics changes, the vibration pattern also changed

• Tandon et al. (year 1992) conducted the condition monitoring on the rolling elements of the bearings by
utilizing the technique of acoustic emissions and vibration analysis of the signals. The writers obtained the
acoustic emission and vibration analysis of signals. They obtained the characteristics like vibration, envelope
vibration, and intensity of sound, pressure of sound and peak amplitude. They ended resulting that the
reliability and accuracy of fault identification and monitoring with acoustic emission and envelope vibration
was much good than any other characteristics.

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• Hariharan et al. (year 2010) studied the effect of the presence of contamination in the lubricant by the solid
particles on the efficiency of bearings. They introduced the contaminants by using the distinct sizes of the
silica powder in different concentrations. The writers observed the vibration data from the healthy and the
contaminated bearing for the analysis. They discovered that the considerable deflection in RMS value of
vibration for distinct size of particle and the contaminant concentration. The writer received the vibration data
from the several conditions of bearings like healthy bearing, inner race defect, outer race defect and rolling
element defect. The received data sets were analyzed and processed with the wavelet transformation (WT).

• Choudhury et al. (year 2000) used acoustic emission signals to detect the faults in different sized bearings
with the variation in bearing speed from 500 RPM to 1500 RPM. It was observed that healthy (undamaged)
bearings had experienced extremely low values of acoustic emission count. Moreover, it was also observed
that for faulty bearings acoustic emission counts increased significantly with increase in the speed and for the
healthy bearings no considerable variation in acoustic emission count were observed upon increasing the
value load.

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RESEARCH GAP

Most of researchers were carried out their experiments on performance and condition monitoring of bearings to
do an observational analysis on some common parameters like the crest factor, kurtosis curves, and skew values
to detect the defects in bearings some other parameters such as load, contaminant concentration, rotational
speed, feed rate, particle size of contaminant etc. were also used to find their effect on some well-liked output
parameter such as Kurtosis, peak to peak, root mean square values of vibration, temperature of bearing etc.
However, some of the researchers analyze faults in the bearings and their fatigue life using current signal and
measuring surface topography respectively but there are merely few researchers who are doing any
statistical analysis, different from the general observational analysis carried out by most of the
researchers, and optimization of some input parameters to find their effect on different values of vibrations.

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OBJECTIVE

To identify the bearing


failure

To study the effect of


different machining or
process parameters

To optimize the Data using


particle swarm
optimization

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EXPERIMENTAL SETUP

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RESEARCH METHODOLOGY
Literature Survey

Define Objective

Experimental Setup
• 6205 Ball Bearing (Healthy and contaminated)
• Variable Speed
• Variable Load
• Variable concentration

Design Experiments using L16


orthogonal array

Collection of data and it’s statistical analysis


• Regression and ANOVA analysis

Optimization of data using PSO

Validation of optimized results


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DESIGN OF EXPERIMENTS

In order to design our experiments, Taguchi L 16 orthogonal array approach is used. The approach was
implemented by using Minitab 18 software.

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Process parameters and levels

Levels
Sr. No. Process Parameters
Level 1 Level 2 Level 3 Level 4
1 Load (Kg) 0 1 3 5
2 Contaminant Concentration (%) 0 5 10 15
3 Particle size (µm) 70 100
4 RPM 1000 1500

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Designed set of experiments

Sr. No. Load (Kg) Contaminant Concentration (%) Particle size (µm) RPM
1 0 0 70 1000
2 0 5 70 1000
3 0 10 100 1500
4 0 15 100 1500
5 1 0 70 1500
6 1 5 70 1500
7 1 10 100 1000
8 1 15 100 1000
9 3 0 100 1000
10 3 5 100 1000
11 3 10 70 1500
12 3 15 70 1500
13 5 0 100 1500
14 5 5 100 1500
15 5 10 70 1000
16 5 15 70 1000
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Set of experiments with RMS and Peak To Peak
Sr. No Load(kg) Contaminants Concentration (%) Particle size (µm) RPM RMS Peak to peak

1 0 0 70 1000 0.47000 4.625


2 0 5 70 1000 0.55233 5.860
3 0 10 100 1500 0.56400 5.275
4 0 15 100 1500 0.58500 5.574
5 1 0 70 1500 0.48900 4.591
6 1 5 70 1500 0.58500 5.880
7 1 10 100 1000 0.61400 6.641
8 1 15 100 1000 0.63400 7.141
9 3 0 100 1000 0.52100 6.454
10 3 5 100 1000 0.62300 7.995
11 3 10 70 1500 0.66400 7.052
12 3 15 70 1500 0.68500 7.481
13 5 0 100 1500 0.60570 8.066
14 5 5 100 1500 0.68508 9.535
15 5 10 70 1000 0.67300 7.617
16 5 15 70 1000 0.70100 7.724
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RESULTS

ANOVA Table for RMS

Source DF Adj SS Adj MS F-Value P-Value


Regression 6 0.074654 0.012442 168.08 0.000
Load 1 0.001286 0.001286 17.37 0.002
Contaminants Concentration 1 0.016514 0.016514 223.09 0.000
Particle size 1 0.002264 0.002264 30.59 0.000
RPM 1 0.000035 0.000035 0.47 0.508
Contaminants
Concentration*Contaminants 1 0.004546 0.004546 61.42 0.000
Concentration
Load*Particle size 1 0.00295 0.00295 39.86 0.000
Error 9 0.000666 0.000074
Total 15 0.07532
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Regression Equation for RMS

RMS = 0.5929 - 0.0471 Load + 0.02176 Contaminants Concentration - 0.001827 Particle size
+ 0.000006 RPM - 0.000674 Contaminants Concentration*Contaminants Concentration
+ 0.000835 Load*Particle size

• Load is the most significant Input parameter

• RPM is highly insignificant

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ANOVA Table for Peak To Peak

Source DF Adj SS Adj MS F-Value P-Value


Regression 6 27.7072 4.61787 232.48 0.000
Load 1 2.1167 2.11673 106.56 0.000
Contaminants Concentration 1 3.7914 3.79142 190.88 0.000
Particle size 1 1.1657 1.16573 58.69 0.000
RPM 1 0.3302 0.33016 16.62 0.003

Contaminants
Concentration*Contaminants 1 1.1020 1.10198 55.48 0.000
Concentration

Load*Particle size 1 3.6220 3.62201 182.35 0.000


Error 9 0.1788 0.01986
Total 15 27.8860 22
Regression Equation for Peak To Peak

Peak to Peak = 8.130 - 1.911 Load + 0.3297 Contaminants Concentration - 0.04146 Particle size
- 0.000590 RPM - 0.01050 Contaminants Concentration*Contaminants Concentration
+ 0.02926 Load*Particle size

• Load is the most significant Input parameter

• RPM is the least significant input parameter

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Model summary for RMS

S R-sq R-sq(adj) R-sq(pred)


0.0086037 99.12% 98.53% 97.03%

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Model summary for Peak to Peak

S R-sq R-sq(adj) R-sq(pred)


0.140937 99.36% 98.93% 97.79%

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Predicted RMS Value

• To find predicted values of RMS for all set of experiments, we have to put values of all input parameters
from each set one by one in Regression equation for RMS

• Example – Let’s put values of all input parameters from set 1 in regression equation for RMS

Regression equation for RMS is

RMS = 0.5929 - 0.0471 Load + 0.02176 Contaminants Concentration - 0.001827 Particle size
+ 0.000006 RPM - 0.000674 Contaminants Concentration*Contaminants Concentration
+ 0.000835 Load*Particle size

Value of all parameters in Set 1 is as follows

Load = 0 Kg, Contaminant concentration = 0%, Particle size = 70µm, RPM = 1000

RMS = 0.5929 – 0.0471*0 + 0.02176*0 – 0.001827*70 + 0.000006*1000 – 0.000674*0*0 + 0.000835*0*70

RMS = 0.47101
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Predicted RMS

Sr.No Load Contaminants Concentration Particle size RPM Predicted RMS


1 0 0 70 1000 0.47101
2 0 5 70 1000 0.56296
3 0 10 100 1500 0.5694
4 0 15 100 1500 0.59395
5 1 0 70 1500 0.48536
6 1 5 70 1500 0.57731
7 1 10 100 1000 0.6028
8 1 15 100 1000 0.62735
9 3 0 100 1000 0.5254
10 3 5 100 1000 0.61735
11 3 10 70 1500 0.65826
12 3 15 70 1500 0.68281
13 5 0 100 1500 0.6012
14 5 5 100 1500 0.69315
15 5 10 70 1000 0.67796
16 5 15 70 1000 0.70251

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Predicted Peak to Peak Value

• Similarly, we can also find predicted peak to peak value by simply putting the value of each parameter from
all the set in regression equation for peak to peak

Regression equation for Peak to Peak is

Peak to Peak = 8.130 - 1.911 Load + 0.3297 Contaminants Concentration - 0.04146 Particle size
- 0.000590 RPM - 0.01050 Contaminants Concentration*Contaminants Concentration
+ 0.02926 Load*Particle size

Value of all parameters in Set 1 is as follows

Load = 0 Kg, Contaminant concentration = 0%, Particle size = 70µm, RPM = 1000

RMS = 8.130 – 1.911*0 + 0.3297*0 – 0.04146*70 + 0.000590*1000 – 0.01050*0*0 + 0.02926*0*70

RMS = 4.6378

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Predicted Peak to Peak

Sr.No. Load Contaminants Concentration Particle size RPM Predicted Peak to


Peak

1 0 0 70 1000 4.6378
2 0 5 70 1000 6.0238
3 0 10 100 1500 5.346
4 0 15 100 1500 5.682
5 1 0 70 1500 4.48
6 1 5 70 1500 5.866
7 1 10 100 1000 6.656
8 1 15 100 1000 6.992
9 3 0 100 1000 6.439
10 3 5 100 1000 7.825
11 3 10 70 1500 7.0014
12 3 15 70 1500 7.3374
13 5 0 100 1500 8.174
14 5 5 100 1500 9.56
15 5 10 70 1000 7.5708
16 5 15 70 1000 7.9068
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Error Table

Error =
Error = Predicted
Experimental Predicted Experimental Experimental -
Sr.No. Experimental - Peak to
RMS RMS Peak to Peak predicted peak
Predicted RMS Peak
to peak

1 0.47 0.47101 -0.00101 4.625 4.6378 -0.0128


2 0.55233 0.56296 -0.01063 5.86 6.0238 -0.1638
3 0.564 0.5694 -0.0054 5.275 5.346 -0.071
4 0.585 0.59395 -0.00895 5.574 5.682 -0.108
5 0.489 0.48536 0.00364 4.591 4.48 0.111
6 0.585 0.57731 0.00769 5.88 5.866 0.014
7 0.614 0.6028 0.0112 6.641 6.656 -0.015
8 0.634 0.62735 0.00665 7.141 6.992 0.149
9 0.521 0.5254 -0.0044 6.454 6.439 0.015
10 0.623 0.61735 0.00565 7.995 7.825 0.17
11 0.664 0.65826 0.00574 7.052 7.0014 0.0506
12 0.685 0.68281 0.00219 7.481 7.3374 0.1436
13 0.6057 0.6012 0.0045 8.066 8.174 -0.108
14 0.68508 0.69315 -0.00807 9.535 9.56 -0.025
15 0.673 0.67796 -0.00496 7.617 7.5708 0.0462
16 0.701 0.70251 -0.00151 7.724 7.9068 -0.1828
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Comparison between experimental and predicted RMS
0.8

0.7

0.6

RMS 0.5

0.4 Predicted RMS


Linear (Predicted RMS)
Experimental RMS
0.3 Linear (Experimental RMS)

0.2

0.1

0
0 2 4 6 8 10 12 14 16 18

No. of Experiments

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Comparison between experimental and predicted Peak to Peak
12

10

8
Peak to Peak

6 Predicted Peak to Peak


Linear (Predicted Peak to Peak)
Experimental Peak to Peak
Linear (Experimental Peak to Peak)
4

0
0 2 4 6 8 10 12 14 16 18

No. of Experiments

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Effect of different input parameters on RMS value

Effect of Load on RMS Effect of Contaminants Concentration on RMS


0.675 0.66

0.64
0.650

0.62

0.625
0.60
Mean

Mean
0.600 0.58

0.56
0.575

0.54
0.550
0.52
0 1 3 5 0 5 10 15
Load Contaminants Concentration

Effect of Particle size on RMS Effect of RPM on RMS


0.60400 0.608

0.60375
0.606

0.60350

0.604
0.60325
Mean

Mean
0.60300 0.602

0.60275
0.600

0.60250

0.598
70 100 1000 1500
Particle size RPM

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Effect of different input parameters on Peak to Peak value

Effect of Load on Peak to Peak Effect of Contaminants Concentration on Peak to Peak


8.5 7.4

8.0 7.2

7.0
7.5

6.8
7.0
Mean

Mean
6.6
6.5

6.4
6.0
6.2
5.5
6.0
5.0
0 1 3 5 0 5 10 15
Load Contaminants Concentration

Effect of Particle size on Peak to Peak Effect of RPM on Peak to Peak


7.1 6.76

7.0 6.75

6.9 6.74

6.8 6.73
Mean

Mean
6.7 6.72

6.6 6.71

6.5 6.70

6.4 6.69

6.3 6.68
70 100 1000 1500
Particle size RPM

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PARTICLE SWARM OPTIMIZATION

• PSO is an intelligent optimization algorithm


• PSO is a metaheuristic algorithm
• PSO is initially developed by James Kennedy and Russell C. Eberhart
• PSO is inspired by social behaviour of animals like fish and birds

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Principles of PSO

• Communication
• Learning

PSO is a swarm intelligence method and it uses some unintelligent particles to reach an upper level of
intelligence which is absolutely unreachable for any particle in the world.

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Working of PSO

• For every particle (i) position of particle is denoted by

• To distinguish between time steps we add a time index to this position

• In the example of Alice and Bob, at the beginning of search, both of their positions are given by and.

• In addition to position we have a velocity which describes the movement of every particle in terms of
direction and distance and is denoted by

• So, we have a particle in time step (t) which is located in the position and it moves towards a vector

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• In addition to position and velocity every particle has a memory of its own best position called personal best,
denoted by Along with personal best every particle experiences a common best among the members of
swarm called global best denoted by

• On every iteration of PSO position and velocity of every particle is updated according to the simple
mechanism discussed below

Where w is inertia coefficient and , are acceleration coefficient


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Standard PSO equations

⃗ ⃗ ⃗
⃗V𝑖𝑗(𝑡+1)=𝑤∗⃗V𝑖𝑗(𝑡)+𝑟1∗𝑐1∗(𝑃𝑖𝑗(𝑡)−𝑋𝑖𝑗(𝑡))+𝑟2∗𝑐2∗(𝑔𝑗(𝑡)−𝑋𝑖𝑗(𝑡))
Inertia term
Cognitive or individual
component

and are the random number uniformly distributed in the range of 0 and 1
Social Component

• So, we have to combine inertia term, cognitive component and social component in order to obtain a new or
updated velocity vector.

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Sr.No. Iteration number Best RMS
1 Iteration number 1 0.545724807890667
2 Iteration number 2 0.545724807890667
3 Iteration number 3 0.505572550393005
4 Iteration number 4 0.492581779034261
5 Iteration number 5 0.484360820271419
6 Iteration number 6 0.476780078976856
7 Iteration number 7 0.473807495178774
8 Iteration number 8 0.473807495178774
9 Iteration number 9 0.473752359934819
10 Iteration number 10 0.473564322933673
11 Iteration number 11 0.473281894921517
12 Iteration number 12 0.472739954079068
13 Iteration number 13 0.472139954079068
14 Iteration number 14 0.471606708721376
15 Iteration number 15 0.471010000000000
16 Iteration number 16 0.471010000000000
17 Iteration number 17 0.471010000000000
18 Iteration number 18 0.471010000000000
19 Iteration number 19 0.471010000000000
20 Iteration number 20 0.471010000000000
21 Iteration number 21 0.471010000000000
22 Iteration number 22 0.471010000000000
23 Iteration number 23 0.471010000000000
24 Iteration number 24 0.471010000000000
25 Iteration number 25 0.471010000000000
26 Iteration number 26 0.471010000000000
27 Iteration number 27 0.471010000000000
28 Iteration number 28 0.471010000000000
29 Iteration number 29 0.471010000000000
30 Iteration number 30 0.471010000000000
31 Iteration number 31 0.471010000000000
32 Iteration number 32 0.471010000000000
33 Iteration number 33 0.471010000000000
34 Iteration number 34 0.471010000000000
35 Iteration number 35 0.471010000000000
36 Iteration number 36 0.471010000000000
37 Iteration number 37 0.471010000000000
38 Iteration number 38 0.471010000000000
39 Iteration number 39 0.471010000000000
40 Iteration number 40 0.471010000000000
41 Iteration number 41 0.471010000000000
42 Iteration number 42 0.471010000000000
43 Iteration number 43 0.471010000000000
44 Iteration number 44 0.471010000000000
45 Iteration number 45 0.471010000000000
46 Iteration number 46 0.471010000000000
47 Iteration number 47 0.471010000000000
48 Iteration number 48 0.471010000000000
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49 Iteration number 49 0.471010000000000
50 Iteration number 50 0.471010000000000
Results of PSO for RMS Value

Best RMS vs Number of iterations

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Optimal value of process parameters

Load Contaminants Concentration Particle size RPM RMS

0 0 70 1000 0.471010000000000

Minimum value of Root Mean Square obtained by particle swarm optimization is 0.471010000000000.

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Experimental validation for optimized value of RMS

In order to validate the optimized result, experiments were performed on the same process parameters on which
the optimized value of RMS is obtained and calculate RMS value after the experiment. RMS value obtained after
experiment is

Load Contaminants Concentration Particle size RPM RMS


0 0 70 1000 0.446250000000

|𝑅𝑀𝑆 𝑝𝑟𝑒𝑑𝑖𝑐𝑡𝑒𝑑 − 𝑅𝑀𝑆 𝑒𝑥𝑝𝑒𝑟𝑖𝑚𝑒𝑛𝑡𝑎𝑙 |


% 𝑒𝑟𝑟𝑜𝑟 = ∗100
𝑅𝑀𝑆 𝑝𝑟𝑒𝑑𝑖𝑐𝑡𝑒𝑑

As it is known that and . So, from equation % error = 5.2567%.

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Sr.No. Iteration number Best Peak to Peak

1 Iteration number 1 6.60937526156573


2 Iteration number 2 6.60937526156573
3 Iteration number 3 6.10862344094587
4 Iteration number 4 5.89277514602017
5 Iteration number 5 5.13389562969256
6 Iteration number 6 4.95463335199788
7 Iteration number 7 4.87962883336089
8 Iteration number 8 4.82488725135212
9 Iteration number 9 4.78166495984652
10 Iteration number 10 4.72865459941275
11 Iteration number 11 4.63780000000000
12 Iteration number 12 4.63780000000000
13 Iteration number 13 4.63780000000000
14 Iteration number 14 4.63780000000000
15 Iteration number 15 4.63780000000000
16 Iteration number 16 4.63780000000000
17 Iteration number 17 4.63780000000000
18 Iteration number 18 4.63780000000000
19 Iteration number 19 4.63780000000000
20 Iteration number 20 4.63780000000000
21 Iteration number 21 4.63780000000000
22 Iteration number 22 4.63780000000000
23 Iteration number 23 4.63780000000000
24 Iteration number 24 4.63780000000000
25 Iteration number 25 4.63780000000000
26 Iteration number 26 4.63780000000000
27 Iteration number 27 4.63780000000000
28 Iteration number 28 4.63780000000000
29 Iteration number 29 4.63780000000000
30 Iteration number 30 4.63780000000000
31 Iteration number 31 4.63780000000000
32 Iteration number 32 4.63780000000000
33 Iteration number 33 4.63780000000000
34 Iteration number 34 4.63780000000000
35 Iteration number 35 4.63780000000000
36 Iteration number 36 4.63780000000000
37 Iteration number 37 4.63780000000000
38 Iteration number 38 4.63780000000000
39 Iteration number 39 4.63780000000000
40 Iteration number 40 4.63780000000000
41 Iteration number 41 4.63780000000000
42 Iteration number 42 4.63780000000000
43 Iteration number 43 4.63780000000000
44 Iteration number 44 4.63780000000000
45 Iteration number 45 4.63780000000000
46 Iteration number 46 4.63780000000000
47 Iteration number 47 4.63780000000000
48 Iteration number 48 4.63780000000000
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49 Iteration number 49 4.63780000000000
50 Iteration number 50 4.63780000000000
Results of PSO for Peak to Peak Value

Best Peak to Peak vs Number of iterations

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Optimal value of process parameters

Load Contaminants Concentration Particle size RPM Peak to Peak


0 0 70 1000 4.63780000000000

Minimum value of Peak to Peak obtained by particle swarm optimization is 4.63780000000000.

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Experimental validation for optimized value of Peak to Peak

In order to validate the optimized result, experiments were performed on the same process parameters on which
the optimized value of Peak to Peak is obtained and calculate Peak to Peak value after the experiment. Peak to
Peak value obtained after experiment is

Load Contaminants Concentration Particle size RPM Peak to Peak


0 0 70 1000 4.38368000000

|𝑅𝑀𝑆 𝑝𝑟𝑒𝑑𝑖𝑐𝑡𝑒𝑑 − 𝑅𝑀𝑆 𝑒𝑥𝑝𝑒𝑟𝑖𝑚𝑒𝑛𝑡𝑎𝑙 |


% 𝑒𝑟𝑟𝑜𝑟 = ∗100
𝑅𝑀𝑆 𝑝𝑟𝑒𝑑𝑖𝑐𝑡𝑒𝑑

As it is known that and So, from above equation % error = 5.4793%.

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CONCLUSION

 Experiments were carried out on stainless steel bearings using solid concentrations of contaminations under
different speeds and load conditions

 A model was developed in the form of regression equation to establish relation between dependent and
independent variable.

 With the increase in load, Contaminant concentration, particle size and RPM, Root mean square value of
vibration increases.

 With the increase in load and particle size, Peak to Peak value of vibration increases however, Peak to Peak
value decreases with the increase in RPM but with the increase in contaminant concentration peak to peak
value first increases then decreases a little bit and then again increases with the increase in contaminant
concentration.

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 PSO optimized the values of process parameters to minimize the Root mean square value of vibration at a
load of ≈ 0kg, particle size of 70µm, contaminant concentration of ≈ 0 and at 1000 RPM, minimum RMS
value of vibration obtained is 0.446250000000 m/s 2.

 Similarly, process parameters were also optimized to minimize the Peak to Peak value of vibration at a load
of ≈ 0kg, particle size of 70µm, contaminant concentration of ≈ 0 and at 1000 RPM, minimum Peak to Peak
value of vibration obtained is 4.38368000000 m/s 2.

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FUTURE SCOPE

 The data could be obtained for various temperature values under different parameters like load, RPM,
contaminant concentration and particle size of contaminant. Taguchi analysis could be done for various
temperature values so obtained.

 Bearing surface roughness and surface deterioration rate can be find out and rate by which surface erodes
can be predicted by using Taguchi analysis.

 With the introduction of contaminant, lubricant viscosity also varies. The viscosity at various parameters cab
be find out and life of lubricant can be found out by using Taguchi analysis.

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