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Analysis and Prediction of Defect Size and Remaining Useful Life of Thrust Ball Bearings: Modelling and Experiment Procedures

  • Research Article - Mechanical Engineering
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Abstract

A new methodology based on full factorial design (FFD) for the prediction of the size of the spalls on the rolling contact surfaces of thrust ball bearings and its remaining useful life is presented in this research work. The FFD is used to analyse the effect of the following factors: rotational speed, load, spalling size, position of the sensors and frequency range on the vibrations level and the interaction effects between these factors. Data collected from vibratory signals generated by thrust ball bearings operating in the fatigue test rig are used. Statistical analyses show that the full factorial model with sixteen coefficients leads to more precise spalling size estimates. Analysis of variance showed that these results were statistically significant [P value is less than 0.0001 where significance level \(\alpha \) (\(\alpha = 0.05\))]. A modified exponential model used in the prediction of the remaining useful life shows its efficiency and applicability.

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Abbreviations

ANOVA:

Analysis of variance

CF:

Crest factor

CV:

Crest value

DF:

Degree of freedom

DPH:

Defective phase

FFD:

Full factorial design

FFM:

Full factorial model

FFM11:

Full factorial model with 11 coefficients

FFM16:

Full factorial model with 16 coefficients

FFM32:

Full factorial model with 32 coefficients

FME:

Fitted model to experimental data

F value:

Fischer’s ratio

MS:

Mean squares

NDPH:

Non-defective phase

RMS:

Root mean square

RMSacc:

Root mean square of acceleration

\(\hbox {RMS}_{\mathrm{FFM16}}\) :

RMSacc calculated using FFM16 model

\(\hbox {RMS}_{\mathrm{FME}}\) :

RMSacc calculated using FME model

RMSE:

Root mean square Error

RT:

Running time

RUL:

Remaining useful life

SS:

Sum of squares

TBB:

Thrust ball bearing

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Acknowledgements

The authors would like to thank Professor Jean Paul Dron and the team of laboratory MAN/GRESPI of Reims University, France, for collaborating and conducting experiments on the fatigue test rig.

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Correspondence to Mouloud Boumahdi.

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Boumahdi, M., Rechak, S. & Hanini, S. Analysis and Prediction of Defect Size and Remaining Useful Life of Thrust Ball Bearings: Modelling and Experiment Procedures. Arab J Sci Eng 42, 4535–4546 (2017). https://doi.org/10.1007/s13369-017-2550-y

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  • DOI: https://doi.org/10.1007/s13369-017-2550-y

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