A New Method for Monitoring Gears Surface Failures Using Enhanced Image Registration Approach

In this paper, we present an image registration approach to cope with inter-image illumination changes of arbitrary shape in order to monitor the development of micro-pitting in transmission gears. Traditional image registration approaches do not typically account for inter-image illumination variations that negatively affect the geometric registration precision. Given a set of captured images of gear surface degradation with different exposure times and geometric deformations, the correlation between the resulting aligned images is compared to a reference one. The presented image registration approach is used with an online health monitoring system involving the analysis of vibration, acoustic emission and oil debris to follow the development of micro-pitting in transmission gears. The proposed monitoring system achieves more registration precision compared to competing systems. This paper experimentally validates the system's capabilities to detect early gear defects and reliably identify the gradual development of micro-pitting in gears, so that it could be used in predictive health monitoring (PHM) systems and overcome the disadvantages of the most commonly used methods, such as gear flank profile scanning, replica sample analysis and conventional image analysis

A straightforward and low-cost pre-inspection measurement method for small gears

On-line or rapid inspection of parts is essential in streamlining manufacturing processes. A novel pre-inspection method for measuring small gears is proposed. This method requires little specialist equipment outside that normally found in a laboratory or on a shop floor. Gears are measured using a standard optical microscope. These are then processed using an image processing algorithm to give a percentage error in tooth profile. This allows only gears of sufficiently high quality to be “passed on” to more sophisticated inspection techniques. The technique is used to analyse sub-centimetre diameter gears produced using WEDM. It is found that the technique provides a simple but effective method of determining how close a gear is to the required geometry. While the result is basic, it is extremely quick and inexpensive to perform alongside the manufacturing process. This method provides a capability to small companies and production lines for pre-inspection of gears before detailed analysis without purchasing specialist equipment

Mechanical Engineering

The book substantially offers the latest progresses about the important topics of the "Mechanical Engineering" to readers. It includes twenty-eight excellent studies prepared using state-of-art methodologies by professional researchers from different countries. The sections in the book comprise of the following titles: power transmission system, manufacturing processes and system analysis, thermo-fluid systems, simulations and computer applications, and new approaches in mechanical engineering education and organization systems

Analysis of the suction chamber of external gear pumps and their influence on cavitation and volumetric efficiency

Hydraulic machines are faced with increasingly severe performance requirements. The need to design smaller and more powerful machines rotating at higher speeds in order to provide increasing efficiencies, has to face a major limitation: cavitation. A two-dimensional numerical approach, by means of Computational Fluid Dynamics (CFD), has been developed for studying the effect of cavitation in the volumetric efficiency of external gear pumps. Several cavitation models and grid deformation algorithms have been studied, and a method for simulating the contact between solid boundaries has been developed. The velocity field in the inlet chamber has also been experimentally measured by means of Time-Resolved Particle Image Velocimetry (TRPIV) and results have been compared to the numerical ones in order to validate the accuracy of the model. Our two-dimensional model is not able to predict the real volumetric efficiency of the pump, since several simplifications are involved in it. Nevertheless, this model shows to be valid to understand the complex flow patterns that take place inside the pump and to study the influence of cavitation on volumetric efficiency. The influence of the rotational speed of the pump has been analyzed, as well as the effect of the geometry of the inlet chamber, the working pressure, the inlet pressure loss factor, and the flow leakage through the radial clearances of the pump between gears and casing.Postprint (published version

Analysis of the suction chamber of external gear pumps and their influence on cavitation and volumetric efficiency

Hydraulic machines are faced with increasingly severe performance requirements. The need to design smaller and more powerful machines rotating at higher speeds in order to provide increasing efficiencies, has to face a major limitation: cavitation. A two-dimensional numerical approach, by means of Computational Fluid Dynamics (CFD), has been developed for studying the effect of cavitation in the volumetric efficiency of external gear pumps. Several cavitation models and grid deformation algorithms have been studied, and a method for simulating the contact between solid boundaries has been developed. The velocity field in the inlet chamber has also been experimentally measured by means of Time-Resolved Particle Image Velocimetry (TRPIV) and results have been compared to the numerical ones in order to validate the accuracy of the model. Our two-dimensional model is not able to predict the real volumetric efficiency of the pump, since several simplifications are involved in it. Nevertheless, this model shows to be valid to understand the complex flow patterns that take place inside the pump and to study the influence of cavitation on volumetric efficiency. The influence of the rotational speed of the pump has been analyzed, as well as the effect of the geometry of the inlet chamber, the working pressure, the inlet pressure loss factor, and the flow leakage through the radial clearances of the pump between gears and casing

A Rotating Aperture Mask for Small Telescopes

Observing the dynamic interaction between stars and their close stellar neighbors is key to establishing the stars’ orbits, masses, and other properties. Our ability to visually discriminate nearby stars is limited by the power of our telescopes, posing a challenge to astronomers at small observatories that contribute to binary star surveys. Masks placed at the telescope aperture promise to augment the resolving power of telescopes of all sizes, but many of these masks must be manually and repetitively reoriented about the optical axis to achieve their full benefits. This paper introduces a design concept for a mask rotation mechanism that can be adapted to telescopes of different types and proportions, focusing on an implementation for a Celestron C11 Schmidt–Cassegrain optical tube assembly. Mask concepts were first evaluated using diffraction simulation programs, later manufactured, and finally tested on close double stars using a C11. An electronic rotation mechanism was designed, produced, and evaluated. Results show that applying a properly shaped and oriented mask to a C11 enhances contrast in images of double star systems relative to images captured with the unmasked telescope, and they show that the rotation mechanism accurately and repeatably places masks at target orientations with minimal manual effort. Detail drawings of the mask rotation mechanism and code for the software interface are included

Dynamic Model of a Two-Stage Speed Reducer Gearbox for ACC Fans.

Mechanical and Mechatronic Engineerin

Tool Wear Characterisation and Parameter Optimisation in Micro-manufacturing Processes

Increases in demand for miniaturised static parts, actuators and devices has presented challenges in machining; requiring fast advancement in the field. This work examines two processes: Wire Electrical Discharge Machining (WEDM), and micro-milling. While very different processes, both of these have in common the fact that their behaviour and the phenomena seen differ from those seen in conventional subtractive machining. Capability of machine tools has increased to allow highly intricate parts to be produced, but there are significant challenges in achieving excellent surface finish, geometrical accuracy and tool life. WEDM is appropriate for cutting complex shapes without long set-up times, but cutting very thin workpieces represents difficulties in achieving stable machining, while the process results in a recast layer which can affect wear and transmission. This work focuses on investigating optimal parameters for machining micro-gears. This has traditionally been challenging because the limited area for spark generation between wire and workpiece leads to unstable machining, resulting in poor machining rate and surface finish. Investigations into significant machining parameters have taken place, followed by a feasibility study cutting brass gears of 0.3 mm thickness. The results indicate that the depth of the recast layer can be minimised while maintaining an acceptable Material Removal Rate (MRR), by considering gear geometry. This work suggests that WEDM is a valuable tool in prototyping miniature gears. Micro-milling allows small, accurate parts to be produced, but micro-tools wear quickly and unpredictably, therefore tool wear is difficult to measure. This results in a high rate of tool changes and reduced productivity. A protocol for measuring tool wear has been produced to allow a common method to be used across research institutes. This presents a method for analysing and reporting micro-mill tool wear which will allow transfer between research institutions and industry, to extend tool life and improving process efficiency. This protocol has then been used to investigate tool coatings on the micro scale, and compare the tribological processes seen on micro-tools to their macro counterparts. This work has resulted in extended tool life for industrial micro-mills and has been applied to industrial situations

Micropitting and related phenomena in case carburised gears

Micropitting is a form of surface contact fatigue encounteredin bearingsa nd gears, under lubricating conditions, which lead to their premature failure. All gears are susceptible to micropitting, including spur, helical and bevel. Micropitting can occur with all heatt reatmentsa ppliedt o gearsa nd with both, synthetica nd mineral lubricants. It can occur after a relatively short period of operation and, after a certain number of cycles,g earsn eedt o be replacedd ue to the increasedn oisea nd vibrations causedb y the deviations of the tooth profile. Continuing operation of affected gears can lead to a catastrophic type of failure (i. e., tooth breakage). These considerations explain the increasing current interest in micropitting. It has been reported that micropitting in bearings is associated with a specific microstructural transformation in steel, i. e. martensite decay. However, to the authoes knowledge, this transformation has not been reported in gears. In the present work, extensive metallurgical investigations have been carried out and they revealed that the same transformation occurs in gears. The aim of this project was to describe the mechanism of micropitting by taking into account the influence of several controlling factors such as, material, surface finish, lubricant, load, temperature,s peeda nd, slide-to-roll ratio. Their influence is assessed with a fractional factorial experimentadl esign.S everaln on-destructivete chniquesh ave been used in order to monitor the specimen condition during and after running, such as X-ray diffraction, optical profilometry, light microscopy. The mechanical properties of the products of martensite decay, known as dark etching regions, white etching bands and butterflies are highly relevant to the fatigue behaviour of the steel. Nanoindentation and AFM techniquesh aveb eenu sedt o determinet hesep roperties. A micropitting mechanism correlated with the mechanism of martensite decay in gears is suggestedb asedo n thesea nalyses.EThOS - Electronic Theses Online ServiceNewcastle University Research Committee : Caterpillar Inc. : Design Unit - Gear Technology CentreGBUnited Kingdo