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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
Defects in Bearing
Lubrication failure
Contamination
Improper Mounting
Overheating
Corrosion
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
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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
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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14
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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
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
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ANOVA Table for Peak To Peak
Contaminants
Concentration*Contaminants 1 1.1020 1.10198 55.48 0.000
Concentration
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
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Model summary for RMS
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Model summary for Peak to Peak
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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
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 = 0 Kg, Contaminant concentration = 0%, Particle size = 70µm, RPM = 1000
RMS = 0.47101
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Predicted RMS
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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
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 = 0 Kg, Contaminant concentration = 0%, Particle size = 70µm, RPM = 1000
RMS = 4.6378
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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
0.7
0.6
RMS 0.5
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
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10
8
Peak to Peak
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
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
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
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
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
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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
• 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
⃗ ⃗ ⃗
⃗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
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Optimal value of process parameters
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
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Sr.No. Iteration number Best Peak to Peak
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Optimal value of process parameters
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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
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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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