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Effect of spur gear crack on rotor dynamic response

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Abstract

Cracks are the most common faults present in gears and can be caused by adverse operating conditions, defects in the material, or simply by fatigue. The early detection of this defect helps in the programming of maintenance and prevention of catastrophic failures. Machine vibration-based identification of small cracks in spur gears is still challenging. This work then proposes a methodology based on signal processing methods to evaluate the effect of this type of crack on the acceleration measured in the position of a geared rotor bearing. To this end, an analytical model of healthy and cracked gear is used to represent such an effect. The rotor is modeled by the finite element method (FEM). Thus, a mixed finite element model with gear representation is proposed to represent the machine and obtain the dynamic response in the bearing support. The acceleration signal in this point, for various crack levels, was obtained and the power spectrum of the mode functions obtained by the empirical decomposition method was evaluated, and the result was promising to identify cracks smaller than 1 mm. To confirm these results, an experimental bench was proposed and the results were as expected. The same method was applied to a set of data from an experiment performed in another scientific study and its validity was also confirmed in this case. This work then presents a new method for identifying cracks in geared rotors, based on the decomposition of the acceleration signal of the system and evaluation of its power spectrum.

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Acknowledgements

The authors thank Espaço da Escrita - Pró-Reitoria de Pesquisa-UNICAMP—for the language services provided and Petrobras and National Council for Scientific and Technological Development, Brazil (CNPq—Grant Number 306150/2021-2) for providing financial support to this research.

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Authors and Affiliations

  1. Department of Mechanical Engineering, School of Technology (FT), University of Brasília, Brasília, 70910-900, Federal District, Brazil

    Laís Bittencourt Visnadi

  2. School of Mechanical Engineering, Unicamp, Mendeleyev St. 200, Campinas, 13083-860, São Paulo, Brazil

    Laís Bittencourt Visnadi, Lucas Nogueira Garpelli, Jony Javorski Eckert, Franco Giuseppe Dedini & Hélio Fiori de Castro

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  1. Laís Bittencourt Visnadi
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  2. Lucas Nogueira Garpelli
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  5. Hélio Fiori de Castro
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Correspondence to Laís Bittencourt Visnadi.

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Visnadi, L.B., Garpelli, L.N., Eckert, J.J. et al. Effect of spur gear crack on rotor dynamic response. J Braz. Soc. Mech. Sci. Eng. 46, 331 (2024). https://doi.org/10.1007/s40430-024-04915-w

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