A

Project Phase -II Report On

Detection of Faults in Ball Bearing Using

Vibrational Analysis

Sant Dnyaneshwar Shikshan Sanstha's

ANNASAHEB DANGE COLLEGE OF ENGINEERING
AND TECHNOLOGY, ASHTA.

Submitted by:
1. Mr. PATIL SHUBHAM BHUPAL
2. Mr. PATIL SANKET SANJAY
3. Mr. PAWAR SWAPNIL UDAY
4. Mr. RAJPUT OMKARSING NITINSING
5. Mr. SAPKAL AMEYA SAMPAT
Sponsored By:
AG Technologies Private Ltd.
Under The Guidance Of
Mr.S.H.KALASKAR
DEPARTMENT OF MECHANICAL ENGINEERING
2016-2017
 ANNASAHEB DANGE COLLEGE OF ENGINEERING
AND TECHNOLOGY, ASHTA.
Tal.-Walwa, Dist. -Sangli, Maharashtra (India) 416 301

Department of Mechanical Engineering

CERTIFICATE
This is to certify that, the following students of B.E. Mechanical Engineering have
successfully completed the project entitled

DETECTION OF FAULTS IN BALL BEARING USING

VIBRATIONAL ANALYSIS
Submitted by

1. Mr. PATIL SHUBHAM BHUPAL

2. Mr. PATIL SANKET SANJAY
3. Mr. PAWAR SWAPNIL UDAY
4. Mr. RAJPUT OMKARSING NITINSING
5. Mr. SAPKAL AMEYA SAMPAT

Is a bonafide record of their own work carried out by them in partial

fulfillment for the award of: -Bachelor of Engineering of SHIVAJI UNIVERSITY,
Kolhapur.
Under my supervision and guidance during the academic year 2016-2017.

Mr.S.H.KALASKAR Dr.S.S.AHANKARI Dr.A.M.MULLA

GUIDE H.O.D PRINCIPAL
 ACKNOWLEDGEMENT

I wish to express my sincere thanks and deep sense of gratitude towards my

guide Prof.S.H.KALASKAR for his guidance, valuable suggestions and constant
encouragement in all phase. I am highly indebted to him for his help in solving my
difficulties, which come across during whole project work on DETECTION OF
FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS.
We are grateful to Prof.M.M.JADHAV for their positive cooperation and
immense kindly help during the period of project with them.
Finally I extend my sincere thanks to respected Dr. S.S.Ahankari
(H.O.D. Mech. Department) and all staff members for their kind support and
encouragement for this project.
Last but not least, we wish to thank my friends for their unconditional love
and support.

With warm regards,

SR.NO. NAME ROLL NO. SIGN

1 Mr. PATIL SHUBHAM BHUPAL 829
2 Mr. PATIL SANKET SANJAY 830
3 Mr. PAWAR SWAPNIL UDAY 833
4 Mr. RAJPUT OMKARSING NITINSING 837
5 Mr. SAPKAL AMEYA SAMPAT 846
TABLE OF CONTENTS:

Sr.
Title Page No.
No.
Abstract I
1 Introduction
1.1 Bearing 01
1.2 Bearing material 02

1.3 Bearing defects 03

1.4 Causes of bearing failure 04

2 Literature Review 09

3 Selection 13

3.1 Selection of Motor 13

3.2 Selection of V-belt & pulley 13

3.3 Selection of Shaft 17

3.4 Selection of key 18

3.5 Selection of Bearing 19

4 Condition Monitoring 20

4.1 Introduction 20

4.2 Condition Monitoring Techniques 20

4.3 Vibration Monitoring 22

4.4 Instrumentation System For Condition Monitoring 22

5 Analysis of Bearing By FFT Analyzer 24

5.1 Introduction 25
Sr.
Title Page No.
No.
5.2 Instrumentation Used For Analysis 25
6 Vibration Measuring Techniques 31
6.1 Introduction 32
6.2 Time Domain Analysis 32

6.3 Frequency Domain Analysis 33

6.4 Vibration Measurement System 34

7 Experimental Setup 36

8 Experimental Procedure 38

9 Results and Conclusion 39

9.1 Experimental Results 39

9.2 Conclusion 43

10 References 44
LIST OF FIGURES:

Sr. No. Figure Name Page No.

1 Bearing Fatigue 5
2 Bearing Corrosion 6
3 Bearing Misalignment 7
4 Cross-section of V-belt 12
5 V-grooved pulley 12
6 Open belt drive 13
7 Experimental Setup 27
8 Vibration spectrum of healthy bearing 39
9 Vibration spectrum of bearing with inner race defects 40
10 Vibration spectrum of bearing with outer race defects 41
11 Vibration spectrum of bearing with defected ball 42

LIST OF TABLES

Sr. No. Table Name Page No.

1 Causes and Remedies of bearing defects 08
2 Ball bearing parameters 16
ABSTRACT

In this work, vibration analysis of rolling element bearings defects is studied.

The REBs are the most widely used mechanical parts in rotating machinery under
high load and high rotational speeds. When the defect in a rolling element comes into
contact with another element surface, an impact force is generated which is resulting
in an impulsive response of the bearing. A defect at any element of the REB transmits
to all other elements such as outer race, inner race, ball and, train cage of the bearing.
The defect in rolling elements may lead to serious catastrophic consequences resulting
in costly downtime. For this purpose, the vibration analysis technique which is a
reliable and accurately detecting defect in the bearing elements is used.[2] The
vibration data captured and used for determination and validation is composed from
four different defects states of the REB without lubrication, inner raceway defect,
ball defect, and foreign particles comes in contact with balls- and one representing
normal state of the bearing for four different running speeds with two load levels. The
results obtained from the experiments have illustrated and explained.
 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

1. INTRODUCTION

1.1 Bearing:
A bearing is a machine element that constrains relative motion to only the desired
motion, and reduces friction between moving parts. The design of the bearing may,
for example, provide for free linear movement of the moving part or for free rotation
around a fixed axis; or, it may prevent a motion by controlling the vectors of normal
forces that bear on the moving parts. Many bearings also facilitate the desired motion
as much as possible, such as by minimizing friction. Bearings are classified broadly
according to the type of operation, the motions allowed, or to the directions of the
loads (forces) applied to the parts.
The term "bearing" is derived from the verb "to bear"; a bearing being a machine
element that allows one part to bear (i.e., to support) another. The simplest bearings
are bearing surfaces, cut or formed into a part, with varying degrees of control over
the form, size, roughness and location of the surface. Other bearings are separate
devices installed into a machine or machine part. The most sophisticated bearings for
the most demanding applications are very precise devices; their manufacture requires
some of the highest standards of current technology [1].
Things tend to roll better than slide and that concept works behind bearings. For
example wheels in your bike are same as bearings, which facilitate its movement. Just
think how much it would be difficult without wheels.
When things slide, there is a relative motion between two surfaces involved.
Due to the friction between the two surfaces a force tend to slow down the motion and
finally stop the motion. But if the two surfaces roll over each other instead of sliding,
friction is greatly reduced and the motion becomes smooth. Bearings reduce friction
by providing smooth metal balls, and a smooth inner and outer metal surface for the
balls to roll against. These balls bear the load and allow the device to spin smoothly.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

1.1 Bearing Material

Bearings are made of a variety of materials of which the most common and
important is stainless steel. Since bearings have to bear a lot of stress, the steel with
which it is made needs to be very strong. The quality of steel used determines the
durability of the bearing. Cheap bearings are made of hardened carbon-steel or
pressed sheet metal, both of which are usually not recommended. The standard
industry classification for the steel in some bearings is 52100, which contains 1%
chromium and 1% carbon. Such steels can be made very hard and tough by heat
treating. 440C stainless steel is used to manufacture bearings which can face rusting
threats.
The diversified applications of bearings in different industry and instruments
have forced engineers to discover new materials for making bearings that suit specific
applications. For example ceramics has become quite popular in making skateboard
bearings. Apart from stainless steel other materials used for manufacturing metallic
bearings include bronze, nickel, brass, iron, aluminum, copper, etc. Materials used for
manufacturing nonmetallic bearings include ceramics, glass, plastics (e.g., nylon,
polyoxymethylene, Teflon, UHMWPE, etc.), and even sapphire.
Shafts are generally supported by two bearings in the radial and axial
directions. The side that fixes relative movement of the shaft and housing in the axial
direction is called the fixed side bearing," and the side that allows movement is
called the "floating side bearing."
The floating side bearing is needed to absorb mounting error and avoid stress
caused by expansion and contraction of the shaft due to temperature change. Wood
was the main material for making bearing in ancient ages.
A large majority of rotating machineries rely on rolling element bearings. Due
to necessity and vital contribution to most rotating machineries, the requirements on
the bearings have become stricter every day. The bearings provide relative positioning
and rotating freedom while usually transmitting a load between shaft and housing
Rotating machineries are complex and have numerous components that could
potentially fail. An analysis should be made to identify the bearings defects before
they become catastrophically fail with the associated downtime costs and significant

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

damage to other parts of rotating machineries. The vibration spectrum analysis is a

popular technique among others such as time domain and time frequency domain for
Tracking machinery, operating conditions, intensive signature magnitude. The
results obtained from the experiments have illustrated and explained. Research has
been done in recent years for the REBs defect diagnosis to ensure the performance
and extend the bearing life. In this study, the different type of the REB defects cases
with respected to two different load level is taken in account since the load affects the
defect signature magnitude. The results obtained from the experiments have
illustrated and explained.[4]

1.2 Bearing Defects

The geometry and dimensions of the REB which consists of outer race, inner
race, and balls are shown in Fig. 1. Defects in the REB produce a series of impacts
which repeat periodically at a rate known as the bearing frequencies. The different
defects occurring in the REB can be classified according to the damaged elements as:
outer raceway defect, inner raceway defect, ball defect, and combination of bearing
components defect. Each bearing element has a characteristic defect frequency that
depends on mechanical dimensions of the bearing. The product of multipliers with the
shaft rotational speed gives the defect frequency of bearing running at given shaft
speed . By identifying the type of the bearing characteristics frequency, the cause of
the defect can be determined. The bearing frequency multipliers equations provide a
theoretical estimate of the frequency to be expected when the bearing elements defect
takes place.

1.3 Causes of Bearing Failures:

The primary causes of bearing failures are:
1. Contamination, including moisture (Some sources claim that 40 percent of
bearing failures are caused by contamination. This is certainly believable based on my
field experience.)[4]
2. Overstress.
3. Lack of lubrication.
4. Defects created after manufacturing.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

Common Causes of Bearing Failures:

There are many causes of bearing damage. It is not always easy to determine
the exact cause, but most bearing failures can be attributed to one or more of the
following major causes:
Foreign Matter
One of the most common sources of trouble in bearings is wear and pitting
caused by foreign particles. This could be in the form of dirt, abrasive grit, lint, dust,
steel chips, etc.
Improper Mounting
Bearings should be mounted with a press fit on the rotating ring. Generally,
the shaft rotates and the inner ring is mounted with a press or interference fit.
Mounting bearings on shafts by applying blows or pressure to the outer race will
usually cause denting (true brinell).
Loose shaft fit
Rotation of the shaft within the inner ring can produce heat and small loose
particles of metal that will eventually get into the bearing, causing wear.
Loose housing fit
Damage similar to loose shaft fit.
Excessive tight fits
Usually causes excessive internal preload because of the removal of internal
clearance. Causes high operating temperature and premature failure.
Out of round housings
Usually found in split housings where careful machining is necessary to obtain
round housing. Causes localized overloading with abnormal wear on surfaces and
retainer pockets. Early fatigue occurs in these areas.
Vibration Brinell (False Brinell):
Caused by the rapid movement of the balls in the raceway while the
equipment is idle. Rolling elements quickly remove lubrication and, because there is
not enough rotation of the bearing, fresh lubricant is not moved back into the spot.
This means the bearing is sitting in one spot, devoid of lubrication, and the movement
of the rolling elements wears away the metal. The indentations run axially across the
races.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

Bearing Fatigue:
Fatigue means the fatiguing of the metal in the components of the bearing. It is
a result of stress reversals produced when rotating members create flexing of the
metal.

Fig.1 Bearing Fatigue

Fatigue failure-usually referred to as spalling-is the fracture of the running

surfaces and subsequent removal of small. Discrete particles of material. Spalling can
occur on the inner ring, outer ring, or balls. This type of failure is progressive and
once initiated will spread as a result of further operation. It will always be
accompanied by a marked increase in vibration, indicating an abnormality. The
remedy is to replace the bearing or consider redesigning to use a bearing having a
greater calculated fatigue life.
Fatigue develops due to the magnitude of the load and the number of times it is
repeated. Actually, the rolling elements create a wave of metal in front of them as
they roll. Thus, the metal in the components is alternately put in tension and then
compression. This action eventually results in flaking of the metal.

Defective Sealing:
This enables foreign material and contaminants to enter the bearing, causing
wear.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

Improper Bearing Lubrication:

Lack of or improper lubrication generally causes overheating or excessive wear
in the bearing. These conditions can result from insufficient lubrication, improper
lubricants, complete absence of lubrication, or insufficient lubrication due to loss
through leakage. Also to be considered is the breakdown of lubricants either by
oxidation or exposure to atmospheric conditions.
Bearing Corrosion:
The finely finished surfaces of ball and roller bearings are readily subject to
corrosion by water, acids, and other agents. Corrosion is basically abrasive in nature
and will account for excessive or abnormal wear in bearings.

Fig.2 Corrosion
Common causes of corrosion include moisture, acid action, poor or broken down
greases, poor wrappings, and condensation resulting from excessive temperature
reversals.
Electrical Damage (Fluting):
When electric currents pass through a bearing, there is arcing and burning at the
points between the races and the rolling elements where the current jumps the air gap.
A line of small burns along the line of contact of the rolling elements is caused by a
low current constantly passing through the bearing. This fluting or grooving is formed
on all parts as the current continues to pass through the bearing, and the contact points

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

change as the bearing rotates. The steel melts in the affected zone. Electrical damage
will cause early spalling and results in a noisy bearing which will have to be replaced.
Improper Bearing Lubrication:
Lack of or improper lubrication generally causes overheating or excessive wear
in the bearing. These conditions can result from insufficient lubrication, improper
lubricants, complete absence of lubrication, or insufficient lubrication due to loss
through leakage. Also to be considered is the breakdown of lubricants either by
oxidation or exposure to atmospheric conditions.
High Temperatures:
High temperatures frequently cause premature bearing failure, the nature of the
failure being predicated on the temperature to which the bearing is raised and the
grease with which it is lubricated. Mild temperature elevations may cause grease to
bleed which reduces the efficiency of the lubricant. Under increasingly elevated
temperature conditions, oxidation causes loss of lubricating elements and the
formation of carbon. The carbon thus formed may lock or jam the bearing. High
temperatures may also reduce the hardness of the metal causing early failure. High
temperatures can cause loss of internal clearance and preloading results. Many
bearing failures can be traced to dirt. Cleanliness is always a must.
Bearing Misalignment
A frequent source of trouble resulting in overheating and separator failure.
Common causes are bent shafts, out-of-square shaft shoulders, out-of-square spacers,
and out-of-square clamping nuts. Inspection of the raceways will show the ball track
veering from one side to the other.

Fig.3 Bearing Misalignment

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS
Sr.No. Causes
1 Foreign Matter
2 Lubricant Failure
3 Excessive tight fits
4 Bearing Misalignment
Vibration Brinell (False
5 such as molybdenumdisulfide when bearing only
Brinell)
6 Bearing Fatigue
7 Corrosion
Table 1. Causes and remedies of bearing defects
Remedies
Clean work areas, tools, fixtures and hands help
reduce contamination failures. Keep grinding
operations away from bearing assembly areas
and keep bearings in their original packaging
until you are ready to install them. Seals are
critical-damaged or inoperative seals cannot
protect bearing from contamination.
Use the most suitable lubricant and quantity.
Decrease in total interference-better matching of
bearings to shafts and housings-taking into
consideration the differences in materials and
operating temperatures.
Inspecting shah and housings for run out of
shoulders and bearing seats; use of single point-
turned or ground threads on non-hardened
shafts and ground threads only on hardened
shafts; and using precision grade locknut.
By isolating bearings from external vibration,
and using greases containing anti-wear additive
oscillate or reverse rapidly as in actuator
motors.
Replace the bearing or consider redesigning to
use a bearing having a greater calculated fatigue
life.
By diverting corrosive fluids away from bearing
areas and use integrally sealed bearings when-
ever possible. If the environment is particularly
hostile, the use of external seals in addition to
integral seals should be considered.
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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

2. LITERATURE REVIEW

(1). Vinod Patel in his Vibrations Generated by Rolling Element Bearings having
Multiple Local Defects on Races used one of the most effective techniques to use
for condition monitoring of the REB is vibration spectrum analysis. Vibration analysis
is a critical for condition monitoring to find the location, cause, and severity of
defects. In this study, normal state condition bearing and deliberately defected
bearings were tested under different shaft running speeds (17 Hz, 25 Hz, 33 Hz, and
41 Hz) with two load levels.
(i) With healthy bearing under no load conditions, the vibration peaks at shaft
rotational frequency with their harmonics are observed.
(ii) With dynamic radial loading of varying frequency applied on the healthy
test bearings, the amplitude of vibrations at the shaft rotation frequency gets buried
under other types of vibrations.
(iii) Overall vibration increases in presence of local defects in comparison to
healthy test bearing under dynamic radial loading.
(iv) With increase in the circular defect size, the vibration peaks at BPFI and
BPFO are getting visible. This visibility is better with local defects on outer race in
comparison to inner race defects.

(2) Mr. Shaha Rohit D, Prof. S. S. Kulkarni in his Vibration Analysis of

deep groove ball bearing using Finite Element Analysis paper modern trend of
dynamic analysis is used for prediction. ANSYS software is used for the modeling
and model analysis of the bearing rotor system. Experiment result has been taken for
the analysis of the signal that has been obtained through the use of FFT analyzer.
Defect size was 0.02 mm^3 was studied and the different plots in terms of
acceleration and displacement amplitude were generated both in the experiment and
FEA software ANSYS.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

(3) H.Mohamadi Monavar, H.Ahmadi in his Prediction of defects in roller

bearings using vibration signal analysis. The vibration monitoring technique is
suitable to analyze various defects in bearing. This technique can provide early
information about progressing malfunctions. This paper describes the suitability of
vibration monitoring and analysis techniques to detect defects in roller bearings. Tri
axial vibration measurements were taken at each end of the coupling on the motor and
rotor bearing housings. The results indicate that bad bearing has a strong effect on the
vibration spectra. Time domain analysis, vibration spectrum analysis have been
employed to identify different defects in bearings. The results have demonstrated that
each one of these techniques is useful to detect problems in roller bearings.

(4) H. Saruhan, S. Sardemir, in his paper, Vibration Analysis of Rolling Element

Bearings Defects observed that, By identifying the type of the bearing
characteristics frequency, the cause of the defect can be determined. The bearing
frequency multipliers equations provide a theoretical estimate of the frequency to be
expected when the bearing elements defect takes place.
The different defects occurring in the REB can be classified according to the
damaged elements as: outer raceway defect, inner raceway defect, ball defect, and
combination of bearing components defect. Each bearing element has a characteristic
defect frequency that depends on mechanical dimensions of the bearing. The product
of multipliers with the shaft rotational speed gives the defect frequency of bearing
running at given shaft speed.

(5) S. V. Shelke, A.G.Thakur , in his Condition Monitoring of Ball Bearing Using

Vibration Analysis and Feature Extraction Introduced the following equations:
A. Ball Pass frequency outer race (BPFO):
If the bearing inner race has a defect such as crack, the fundamental vibration
frequency resulting from ball passing over the defect is called Ball Pass Frequency
Outer race (BPFO) and obtained as;

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

B. Ball Pass frequency inner race (BPFI):

If the bearing inner race has a defect such as crack, the fundamental vibration
frequency resulting from ball passing over the defect is called Ball Pass Inner Race
frequency (BPFI) and obtained as;

C. Ball Spin Frequency (BSF):

If roller or ball has a defect such as pit, the pulse repetition rate occurs each time, the
defect is struck, is known as the Ball Spin Frequency (BSF) and obtained as;

D. Fundamental Train Frequency (FTF):

For a defect occurring in the bearing cage, the Fundamental Train Frequency (FTF) is
given by

Where d is ball diameter, D is pitch diameter, n is number of balls and N is

shaft rotation in RPM, is contact angle .

(5) Surojit Poddar in his paper, Ball Bearing Fault Detection Using Vibration
Parameters Studied the FFT spectrum of faulty ball bearing having three different
defects-inner race defect, outer race defect and ball defect and experimentally verified
the results obtained by therautical equations.

(6) Sakshi Kokil in his paper, Detection of Fault in Rolling Element Bearing using
Condition Monitoring by Experimental Approach observed that, vibration amplitude
decreases with increase in load. When at constant speed and constant load but defect
positions are compared that is vibration amplitudes of defect present on inner race and

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

outer race is compared, it is found that vibration amplitude at inner race is slightly less
than that of outer race. Hence, outer race defect is more severe. Condition monitoring
can be done by time domain and frequency domain technique. Time data graphs are
acquired and observed. It was found that, data extraction from time domain signals is
very difficult because it can detect presence of fault but unable to detect exact
location.

(7) N. Tanden, A. choudhari, in his paper A review of vibration and acoustic

measurement methods for the detection of defects in rolling element
bearingsobserved that, The interaction of defects in rolling element beings produces
pulses of very short duration whenever the defect strikes or is stuck owing to the
rotational motion of the system. These pulses excite the natural frequencies of bearing
elements and housing structures, resulting in an increase vibrational energy at these
frequencies. The resonant frequencies of the individual bearing elements can be
calculated theoretically.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

3. SELECTION

3.1 Selection of Motor

A single phase ac motor is selected in experimental setup. The rated power of

the motor is HP (=.37KW) & that of speed is 1440 rpm.

3.2 Selection of V-Belt & Pulley

This problem illustrated a typical design condition where power required to be
transmitted between shafts. Rubber belts are usually good for such applications
because of their low cost, ready availability for replacement, quiet and efficient
operation. Also wear can be readily noted by simple examination of the belt. V-belts
are durable, inexpensive, and widely available and have sufficient capacity for the
power needed. Also the effective coefficient of friction is more on v-belts than flat
belt. In practice, designer has to select a V-belt from the catalogue of the
manufacturer. [4]
Selection of a belt type is depends upon factors such as Type of driving unit,
Type of driven machine, Operational hours per day, Power to br transmitted, input
and output speeds and approximate center distance depending upon the availability of
space. The selection of V-belt and pulley is given in following steps.

Step 1: Determination of correction factor

The load correction factor (Fa) for this application is 1 since in this
experimental set-up a motor of 0.37 kW power is used.

Step 2: Calculation of design power

Design power (P) = (Fa) (transmitted power) (2.1)
= 1 (0.37)
= 0.37 KW

Step 3: Plotting a graph of design power (0.37 KW) Vs. input speed (1440 rpm)
Recommended belt cross section is of A type. But by considering factor of
safety for aluminum pulleys belt cross section B type is selected as shown in fig. 5.1

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

Belt Selection- B Type

Pitch width (Wp) = 14 mm
Nominal top width (W) = 17 mm
Nominal Height (T) = 11 mm

Fig. 4 Cross sections of V belt Fig.5 V grooved Pulley

Stepped V-grooved pulley made of Aluminum is selected having diameters as

128 mm 108.8 mm and 78 mm as shown in fig.

Step 4: Determination of belt length required for this application

The dimensions of belt drive are as follows
s= wrap angle for small pulley (degrees)
b= wrap angle for big pulley (degrees)
D = diameter of big pulley (mm)
d = diameter of small pulley (mm)
C = center distance (mm)

Space available for center distance is about 200 mm.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

Fig.6 Open belt drive

Stage I) D = 128 mm, d = 78 mm and C = 200 mm

Dd
s = 180 2sin1 ( ) (2.2)
2C
12878
s = 180 2sin1 ( 2200 ) = 165. 340
165.340
s = 165. 340 = ( ) = 2.88 rad
180
(D+d) (Dd)2
Length of belt (L) = 2C + + (2.3)
2 4C
(128+78) (12878)2
(L) = 2 (200) + +
2 4(200)

Therefore the length of a belt used is 28.38 ~ 29 inches.

Stage II) D = 128 mm, d = 78 mm and C = 200 mm

From Eq. (2.2)
Dd
s = 180 2sin1 ( )
2C
12878
s = 180 2sin1 ( 2200 ) = 165. 340
165.340
s 165. 340 = ( ) = 2.88 rad
180

From Eq. (2.3)

(D+d) (Dd)2
Length of belt (L) = 2C + +
2 4C
(128+78) (12878)2
(L) = 2 (200) + +
2 4(200)

= 726.70mm = 28.38 in.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

Step 5
I) Determination of number of belts and tension acting on V belts at 900 rpm
Diameter of driving pulley (D) = 128 mm
Groove angle () = 340
Diameter of driving pulley (d) = 78 mm
Mass of belt (m) = 0.3 kg/m
Max. Permissible tension in belt = 300 N
Power to be transmitted (kW) = 0.37 kW
Wrap of smaller pulley (s) = 2.88 rad
Coefficient of friction for aluminum (f) = 0.15
2
[1 2 ] = /(/2) (2.4)
2

Where,
1 = ()
2 = ()

0.15(2.88)
(sin(/2))
= = 1.48
(34/2)

/(/2) = 1.48 = 4.40

= 60103 (2.5)

1281440
= 60103

= 9.65/

. (2.4),

P1 - 4.40P2 = -94.96 (a)

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

(1 2 )
= (2.5)
1000

(1 2 )(9.65)
0.37 = 1000

1 2 = 38.34 N (b)

() & (),

1 = 77.57
2 = 39.23

.
2 = (2.6)

77.57
= = 0.25 1
300

1. Number of belts required = 1

2. Tension in loose side P1 = 78 N
3. Tension in tight side P2 = 39 N

3.3 Selection of Shaft

Step 1: Material of shaft

We have selected 45C8 shaft for this setup.

Step 2: Permissible shear stress

0.5
=

0.5380
=
3

=63.33 N/mm2

& P1 = 78 N

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

P2=39 N

Step 3: Torque transmitted

Torque transmitted = (78-39) (64)

= 2496 N-mm

Step 4: Bending moment

Mb at B= Mb at C = (P1 +P2) (R)

= (117) (128)

= 14976 N-mm

Step 5: Shaft Diameter

16
= 63.33 = 3 2 + 2

Hence d = 10.68 mm
We have selected shaft 45C8 having a diameter of 20 mm on strength
basis.

3.4 Selection of Key

The key with rectangular cross-section is selected having following
specifications:
b = 3mm
h = 3mm
l = 1.5D = (1.5) (20) =30 mm

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

3.5 Selection of Bearing

The bearing is selected from manufactures catalogue having specifications:

Outer diameter, D(mm) 32

Inner diameter, d(mm) 20
Axial Width, B(mm) 7
Static Load Capacity(N) 1500
Dynamic Load Capacity(N) 2700
Designation No. 61804

Table 2: Ball bearing parameters detail.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

4. CONDITION MONITORING

4.1. Introduction:
Condition monitoring of machines implies, the determination of condition of a
machine and its change with time. The condition of the machines may be determined
by measuring physical parameters like: vibration, noise, temperature, wear debris, oil
contamination etc.
The changes in this parameters are called as signatures. The signature
indicates the change in condition or health of machine. The analysis of signatures
helps in predicting and preventing the failure of the machine. The above parameters
are measured or monitored continuously or at regular intervals of time, depending
upon the applications.

4.2. Condition Monitoring Techniques:

4.2.1. Visual and Aural Monitoring
4.2.2. Operational Variables Monitoring
4.2.3. Temperature Monitoring
4.2.4. Wear debris Monitoring
4.2.5. Vibration Monitoring

4.2.1. Visual and Aural Monitoring:

Visual and Aural monitoring methods are basic forms of condition
monitoring techniques in which a skilled operator or technician having an intimate
knowledge of machines can identify the failure of machine, just by visual observation
of large amplitudes of vibrations or by listening the sounds caused by the damaged
parts of machine.

4.2.2. Operational Variables Monitoring:

In operation variables monitoring method, the performance of machine is
observed with regards to its function work. Any deviation from the intended
performance indicates a malfunction of the machine.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

4.2.3. Temperature Monitoring:

Temperature monitoring involves measuring the surface temperature of the
machine. A rapid increase in temperature occurs due to more friction and wear of
machine parts which indicates the malfunction such as inadequate lubrication between
two mating parts.
This monitoring technique uses devices like optical pyrometers.
Thermocouples and thermometers etc.

4.2.4. Wear Debris Monitoring:

Wear debris are generated due to friction between two moving surfaces of the
machine parts. These wear particles can be found in the lubricating oils or grease,
which can be used to identify the extent of damage.
If the rate of wear increases, the particles of the material can be found in
increasing concentration. Thus the severity of the wear can be identified by observing
the concentration, size, shape and color of the particles. This mentioning technique is
suitable for condition monitoring of machine components like: bearings, gears CIC.

4.2.5. Vibration Monitoring:

Vibration monitoring is most commonly used {or machine condition
monitoring.Vibration signature of a machine is seen to be very much related to the
health of a machine. Thus measurement of vibration levels of machine component can
provide useful information regarding faults like unbalance, misalignment, lack of oil,
wear, etc.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

4.3. Vibration Monitoring:

4.3.1. Time domain analysis.
4.3.2. Frequency domain analysis.

4.3.1. Time domain analysis:

Time domain analysis uses the acceleration_ time history of signal. The damages such
as broken teeths in gears can be identified easily from the acceleration - time history
of the casing of a gearbox.
4.3.2. Frequency domain analysis:
Frequency domain analysis or frequency spectrum is the plot of amplitude of
vibrations versus frequency, which is converted from time domain signals by using
FFT spectrum analyzer. The frequency Spectrum provides the valuable information
about the condition of machine. A frequency spectrum of any machine is somewhat
unique therefore a s long as the excitation forces are constant or vary by small
amounts. The FFT spectrum indicates the location of the fault. [6]
When the machine starts developing faults,its vibration level or shape of
frequency spectrum change accordingly. By comparing frequency of machine when it
is in good condition, with the frequency spectrum hence it is in damaged condition the
nature and location of fault can be easily detected.
Another advantage of frequency spectrum is that, each element in machine has
identifiable frequency, therefore the change in spectrum at given frequency can be
attributed directly to that corresponding machines component The analytical equation
are available to find the fault frequencies of standard component like: bearing, gear
boxes, motors ,pumps fans ,etc.

4.4. Instrumentation System for Condition Monitoring:

Depend upon the degree of sophistication, following three types of
instrumentation systems can be used for conditioning monitoring of machines:

4.4. 1. Basic Condition Monitoring System

4.4.2. Portable Condition Monitoring System
4.4.3. Computer Based Condition Monitoring System

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

4.4.1. Basic Condition Monitoring System:

The Basic condition monitoring system consist of a simple pocket sized
vibration meter stroboscope and headset, shown in fig. The vibration levels (i.e.
acceleration and velocity) over suitable frequency ranges. The overall Vibration levels
can also be plotted against time to find how rapidly the condition of machine is
varying.
The measured vibration level is compared with standard level set for particular
machine and take corrective action, if is needed. The stroboscope indicates the speed
of machine and headset helps in hearing the machine vibration by an experienced
operator over a period of time and finds its condition.

4.4.2. Portable Condition Monitoring System:

The portable condition monitoring system consists of piezo-electric
accelerometer, FFT analyzer and recorder, as shown in fig. The FFT analyzer stores
the vibration spectrum, taking signals from accelerometer from different measurement
points when machine was in good condition.
Any change in spectrum indicates fault, which needs further investigation. In
case of the data cannot be analyzed in the field, it may be recorder on a magic tape
recorder and it analyzed in the field, it may be recorded on a magic tape recorder and
it analyzed in the laboratory separately such system is called field measuring system.

4.4.3. Computer Based Condition Monitoring System:

In computer based condition monitoring system a mini-computer is used for
analysis and storage of data from a large number of machines. A FFT spectrum
analyzer would give an instantaneous picture of frequency spectrum. Each recorded
spectrum can be compared with a reference spectrum which stored earlier in computer
for important components.
In case any of the Spectrum level exceeds beyond the permissible Spectrum
level, a control signal is sent to the machine is concerned. The output result can also
be printed which is available in the memory bank. The monitoring system is very
useful and economical for monitoring the number of machine.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

4.5. Analysis of Results:

Once the results are taken from vibration monitoring system, the causes
Vibration to take the corrective action .Therefore, knowledge of identifying the
fault from measured data is very important. Following table gives the general
guidelines for identifying the causes of vibrations.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

5. ANALYSIS OF BEARING BY FFT ANALYZER

5.1 Introduction
In this chapter, the details about the experimental analysis for lathe spindle are
given. The test set up used for the analysis is explained with the schematic diagram
along with the necessary state-of-the-art electronic instrumentation is used for the
experimental analysis. The Adash FFT analyzer was used to analysis.
Another application for testing is that of force determination. Given a
theoretical model and measured vibration on a real structure, it is possible to
determine the forces that act upon the real structure. Nevertheless this method is very
sensitive to modeling inaccuracies and little errors can have huge consequences.

5.2 Instrumentation Used for Analysis

Following are the instruments used for the analysis :
FFT Analyzer

Accelerometer

5.2.1. FFT analyzer

A Fast Fourier Transform (FFT) is a device which is used to detect the
potential faults and checking the condition of the machine through the vibrational
analysis. The vibrational parameters such as natural frequency, amplitude, deflection
etc. The FFT device is also called as Vibration analyzer. A FFT is widely used for
Vibration analysis and fault diagnosis of the machines and equipment.
Vibration diagnosis is a fantastic tool for localization of defects and causes of
damage to machines and aggregates, and one which can even be used as an objective
defense against unjustified warranty claims. Also various types of accelerometers and
sensors i.e. piezoelectric sensors used for the experimental analysis which transfers
the vibration signals to the FFT device.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

The vibration data collectors available for use in machine condition

monitoring and fault diagnostics are microcomputer based. They are used together
with vibration sensors to measures vibration, to store and transfer data and for
frequency domain analysis.

The advantage of data collectors is the ability to use these devices to conduct
on-the-spot diagnostics. They are usually used with a PC to provide permanent data
storage and a platform for more detailed analysis software.
Features available with ADASH VA4 FFT Analyzer :
Analyzer,
Data Collector
Run Up measurements,
Balancer
Signal Recorder
All modes made for: 4 AC simultaneous channels,

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

4 DC channels for process values,

1 Tacho channel
A spectrum analyzer is an electronic device that is capable of taking the time
waveform of a given signal and converting it into its frequency domain.

Importance of spectrum analyzer

J. B. Fourier mathematician showed that it is possible to represent any time
waveform (the plot of a signal whose amplitude varies with time) by a series of sins
and cosines of particular frequencies and amplitudes.
Designers have sought ways to simplify their work by looking for the
frequency content of signals. In the machinery, the goal is to relate the various
frequencies seen in spectra (plot amplitude verses frequency) to have various physical
phenomena occurring in a machine. Analog filters are used to measure sound and
vibration of a piece of machinery. But analog filters have major problems that, these
filters require long setting time before accurate amplitude can be measured. Now a
days tunable filters is used, which sweep through the frequency range of interest.
Using FFT, now easily carry out the spectrum analysis of a sound or vibration signal
from a machine.

5.3.2 Two channel spectrum analyzer

A 2-channel spectrum analyzer is far more powerful than signal channel
analyzer. The two-channel analyzer operates in same way as a single channel analyzer
with following exception.
1) Two input attenuators.
2) Two input buffers, controlled by the same analyzer in the internal clock.
3) Half the number of lines of resolution as the same analyzer in the single - channel
mode.
4) Calculation of cross channel properties such as the transfer function, coherence
and coherent -output power.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

5.3.2 Application of FFT Spectrum Analyzer:

A: Vibration magnitude
Measuring the magnitude of vibrations is a useful diagnostic technique for
ascertaining that machinery IS operating normally and checking for signs of possible
problems. For example, when Vibrations exceeding the reference value in the velocity
range (up to 1000 Hz) are detected. The presence of an unbalance. Misalignment or
loosening condition can be suspected. Whereas vibrations in the acceleration range (1
kHz to about [2 to 15 kHz) point to possible bearing or gear problems

B. Using an absolute evaluation standard

Mechanical Vibration - Evaluation of Machine Vibration by Measurements on
Non- Rotating Parts. This is an absolute reference that can be used to judge whether
measured vibration data are normal or not. The vibration velocity RMS values are
used.

C. Using a relative evaluation standard (trend management)

Using the normal condition as a reference, threshold values for caution and
hazard conditions are set. When the caution level is exceeded, monitoring is
reinforced, and detailed diagnosis is performed when the hazard level is exceeded. A
commonly used factor for setting the levels is as follows: caution level = 2 to 3 times
the normal value, hazard level = 2 to 3 times the caution value. After deciding on the
vibration measurement location, measurement direction, and measurement frequency,
a time series graph is commonly used for trend management, comprising
measurement values and other data.

D. Product Quality Control

When testing products on manufacturing lines for unusual vibrations,
frequency analysis can be very helpful. For example, when targeting a specific
frequency, it can be determined whether there are vibration components in the
adjacent frequency range. Using the frequency Spectrum with a known good product
as reference c, comparative analysis can be applied to pass/fail evaluation.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

E. Precision Diagnosis of Rotating Machinery

Bearing problems will cause a significant increase in acceleration values. As
seen in the example, envelope analysis shows the peaks at equal intervals. When the
size, number of rolling elements, axis rotation Speed and other parameters are known,
the primary frequency of the lined-up peaks will provide information about the
problem location. When diagnosing a bearing fault, it is necessary to know the repeat
cycle of the impact waveform. This can be achieved by envelope processing, using
the principle illustrated below

F. Precision Diagnosis of Rotating Machinery

When there is a misalignment, large vibration components that are an integral
multiple of the rotation speed will appear in the axis direction. The type of bearing
joint affects the multiplication factor. In the example shown here, there are large
vibration components with a factor of 3. When two coupled rotating axes are not
properly centered on relation to each other, their centers of rotation will not be in
linear alignment. This is called misalignment, which can be either relative to the core
or the face or a combination of the two. When misalignment occurs, the thus load on
the bearing increase due to end face run-out, resulting in shorter bearing life.

G. Precision Diagnosis of Rotating Machinery

When there is an imbalance, large vibration components at a frequency equal
to the rotation speed will appear in the circumferential direction. Vibrations of other
frequencies will be largely absent. The vibration amplitude is proportional the
imbalance magnitude. At higher rotation speed, the vibration amplitude is
proportional to the square of the rotation frequency. This is a condition where the
center of gravity of a rotating body has shifted from the centerline.
There are various types of imbalance including static imbalance couple
imbalance and dynamic imbalance. When Imbalance occurs, the load on bearing in
the circumferential direction increases, resulting in shorter bearing life.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

5.3.3 Accelerometer
An Accelerometer is a linear seismic transducer utilizing a piezoelectric
element in such a way that an electric charge is proportional to the applied
acceleration Piezoelectric accelerometers utilize a variety of seismic element
configurations. Most are constructed of polycrystalline ceramic piezoelectric
materials because of their ease of manufacture, high piezoelectric sensitivity, and
excellent time and temperature stability.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

6. Vibration Measuring Techniques

6.1 Introduction :
Mechanical vibrations can be represented as complex combination of a spring
and weight, as shown in fig. The basic physical quantities that define vibration are
displacement, velocity and acceleration. By measuring each of these values, the
vibration condition can be assessed.

Displacement
The movement distance (travel) from a reference point is called
displacement.
For example, if a car travels a distance of 100 meters, the displacement
value is 100 m.
When considering vibrations, the movement distance of the vibrating
object from the stationary rest position is the displacement, which changes
between positive and negative values.
Measurement of vibrations in a low frequency range (below 200 Hz)
Cases where displacement as such is critical.
Assessment of wear and damage related to static deformation, such as
the effects of tensile force or compression.
Assessment of contact risks and machining precision.

Velocity
This quantity expresses the amount of change per unit of time. It is
related to the vibration energy.
For example if a car travels a distance of 100 meters in 10 seconds. the
velocity is the distance (100 m) divided by the time (10 8), Le. 10 m/s.
When considering vibrations the displacement magnitude and direction
change over a short span of time, and the velocity therefore is not usually
constant. The following Relationship exists: Velocity = displacement x 2 x
vibration frequency

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

Measurement of vibrations in a medium frequency range(10 Hz to 1

kHz)
Detection of imbalance. Misalignment, bolt loosening, rattles and play
etc.
Assessment of vibration severity
Assessment of metal fatigue

Acceleration
Acceleration is the change in velocity per unit of time. It is
proportional to the impact force or other external force.
For example, if a car traveling at a velocity of 10 m/s changes to a
velocity of 30 m/s over a period of 2 seconds, the acceleration is the change in
velocity (20 m/s) divided by the time (2 s). i.e. 10 m/s.
When considering vibrations, the velocity and direction change over a
short span of time,and the acceleration therefore is not usually constant. The
following relationship exists:
Acceleration = velocity x 2 x vibration frequency
Measurement of vibrations in a high frequency range (above 1 kHz)

6.2 Time domain analysis

Time domain analysis uses the history of the signal (waveform). The signal is
stored in an oscilloscope or a real-time analyzer and any non-steady or transient
impulse are noted. The data extraction from time domain signals is very difficult
because it can detect presence of fault but unable to detect exact location.[9]

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

6.3 Frequency domain analysis

The frequency domain signal or the frequency spectrum is a plot of the
amplitude of vibration response versus the frequency and can be derived by using the
digital fast Fourier analysis of the time waveform.
The frequency spectrum provides valuable information about the condition of
the machine. The vibration of response of a machine is governed not only by its
component but also by its assembly, mounting and installation. Thus the vibration
characteristics of any machine are somewhat unique to that of particular machine. As
long as the excitation forces are constant or vary by small amounts. However, as the
machine starts developing faults, its vibration level is increases and hence the
frequency changes. The vibration spectrum analyses are widely accepted for detecting
malfunctions in bearings. The frequency domain spectrum is more useful since it also
identifies the exact nature of defect in the bearings. [5]

By comparing the frequency spectrum of the machine in the damaged

condition with the reference frequency spectrum corresponding to the machine in
good condition, the nature and location of the fault can be detected.[7] Another
important characteristic of a spectrum is that each rotating element in a machine
generates identifiable frequency.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

6.4 Vibration Measurement System

The motion of the vibrating body is converted in to an electrical signal by the
vibration transducer .In general a transducer is a device that transforms the signal
changes in mechanical quantities (such as displacement, velocity, acceleration, force)
into changes electrical quantities (such as voltage, current).
Since the output signal conversion instrument is used to amplify the to the
required value. The output from the signal conversion instrument can be presented
on display unit for visual inspection, or by recorder by recording device or stored in
a computer for later use .The data can be analyzed to determine the desired vibration
characteristics of the machine structure. Depending upon the quantity measured a
vibration measuring instrument is called a vibrometer, a velocity meter, an
accelerometer, a phase meter, or a frequency meter. If the instrument is designed to
record the measured quantity, then the suffix "meter" is replaced by "graph" .In some
application, we need to vibrate a machine or structure to find its resonance
characteristics.

6.4.1 Conditions of Measurement

The most effective vibration analysis methods for rolling element bearings are
those which utilize the particular characteristics of bearing vibration. Selection of
such methods is of greatest importance when measurements must be performed under
unfavorable conditions. [3]

Favorable conditions of measurement:

(i) The machine must not have any source of impulsive vibration other than
bearings.
(ii) Bearing speed and load must be of sufficient magnitude to generate
impulses.
(iii) There should be a direct transmission path from the bearing to the
transducer mounting, with only one interface between bearing race and mounting face
on the casing, and the mounting should be reasonably central relative to the bearing
load zone.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

Favorable condition- may be realized on simple machines such as pedestal

bearings and pumps. Most complex machines however lack favorable conditions in
one or more respects, with measurement difficulties ranging from slight to severe.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

7. EXPERIMENTAL SETUP

The test rig for the experiments is shown in Fig. 2. The rig consists of shafts
with length of 800 mm and diameter of 20 mm. The shaft is coupled with a flexible
coupling to minimize the effect of the high frequency vibration generated by the
HP motor. Two bearings are fitted in to the mounting housings. The normal state and
defected bearings are installed in the inboard bearing housing for collecting data. Also
the normal state bearing is installed in the outboard bearing housing for all the test
cases. FiFA UC204 type of ball bearings is utilized in the test rig.

Figure 7: {Experimental test rig: (1) HP Motor; (3) Tachometer; (4) Safety cover
(5) Flexible coupling; (6) Bearing housing; (7) Bearing; (8) Shaft; (9) Loader; (10)
Step Pulley (11) Extended rotor deck; (12) Base; (13) Accelerometer; (14) Rubber
isolators.}

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

As a first step, the experiment was utilized for normal state bearing in order to
establish the base-line data. Then data is collected for others four different defect
conditions of the REB.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

8. EXPERIMENTAL PROCEDURE

The experiment was carried out on lathe machine spindle by selecting two
measuring points i.e. right hand and left hand spindle bearing. The instrument used to
carry out the experiment is VA4 FFT analyzer with Adash software. The conditioning
monitoring functions of VA4 FFT analyzer are based on two widely used techniques
namely natural frequency analysis and acceleration analysis.
It is checked with VIBRATION SEVERITY RANGES IN ACCORDANCE
WITH ISO 2372.According to ISO 2372 the machine comes under class-2. The
acceleration was measured by placing the vibration transducer (accelerometers) on
left hand and right hand bearing of the spindle. The experiment was repeated for
different spindle speeds. For the experimentation the FFT manual Adash_A4400 is
used.

Procedure of Experimentation:
1) Connect the accelerometer appropriate channel of FFT to cables.

2) Prepare set-up for analysis and In-pulse software.

3) Mount accelerometer on shaft with the help of magnetic base..

4) Record the response received from accelerometer in frequency domain

5) Repeat the same procedure for other defected bearings.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

9. Results and Conclusion

9.1 Experimental Results

Fig.9.1: Vibration spectrum of healthy bearing

Analysis: The peak at 100 Hz and 40Hz is due to the imbalance and looseness in the
setup.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

Fig.9.2: Vibration spectrum of bearing with inner race defects

Analysis: The peak at 238Hz is the bearing fault frequency of inner race (BPFI).

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

Fig.9.3: Vibration spectrum of bearing with outer race defects.

Analysis: The peak at 147Hz is the bearing fault frequency of outer race (BPFO).

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

Fig. 9.4 Vibration spectrum of bearing with defected ball

Analysis: The peak at 183 Hz is the bearing fault frequency of ball spin (BSF).

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

9.2 Conclusion :
The objective of this project was to study FFT spectrum of faulty ball bearing
having three different defects-inner race defect, outer race defect and ball defect. The
salient points of observation made from FFT spectra are presented below:

From the plots of extracted features against, it is clear that these features have
potential to identify the defects in the bearing as the plots of healthy bearing
and defective bearing are not overlapped.

The BPFI, BPFO and BSF peaks were observed in FFT spectrum of bearing
with inner race defect, outer race defect and ball defect respectively.

The experimental defect frequencies are slightly different from calculated one
as the kinematic equations.

Sr.No. Frequencies Theorotical Experimental

(Hz) (Hz)
1 BPFI 240 238
2 BPFO 144 147
3 BSF 180 183

Where,
BPFI = Ball Pass Frequency Inner Race
BPFO = Ball Pass Frequency Outer Race
BSF = Ball Spin Frequency

The harmonics of shaft rotating frequency and side band around BPFI and
BPFO shows that some looseness and misalignment was there in setup

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

10. References:
[1] V. N. Patel, Vibrations Generated by Rolling Element Bearings having Multiple
Local Defects on Races, 2nd International Conference on Innovations in Automation
and Mechatronics Engineering, ICIAME 2014, P-316.

[2] Mr. Shaha Rohit D, Prof. S. S. Kulkarni ,Vibration Analysis of deep groove ball
bearing using Finite Element Analysis International Journal of Engineering Research
and Applications , 2015, Vol. 5, , pp.44-50

[3] H.Mohamadi Monavar,H. Ahmadi and S.S.Mohtasebi, Prediction of Defects in

Roller Bearings Using Vibration Signal Analysis, World Applied Sciences Journal,
2008, p.-154.

[4] V.B.Bhandari, Design of machine elements, Tata McGraw Hill Publications,

3rd Edition, 2010, pp.-333,349,575,523,596

[5] H.Saruhan, S.Sardemir, Vibration Analysis of Rolling Element Bearings

Defects, Journal of Applied Research and Technology, 2014, Vol.13, pp.386

[6] S.V.Shelke, A.G.Thakur, Y.S.Pathare, Condition Monitoring of Ball Bearing

Using Vibration Analysis and Feature Extraction, International Research Journal of
Engineering and Technology, 2016.Volume.03.

[7] Surojit Poddar, Ball Bearing Fault Detection Using Vibration Parameters
International Journal of Engineering Research & Technology (IJERT), 2013 ,Vol. 2.

[8] R. G. Desavale, Rafiq Abu Kanai, S. P. Chavan, Vibration Characteristics

Diagnosis of Roller Bearing Using the New Empirical Model Journal of
Tribology(ASME), 2016, Vol. 138,pp.3-8

[9] Sakshi Kokil, Prof.S.Y.Gajjal, Detection of Fault in Rolling Element Bearing

Using Condition Monitoring by Experimental Approach International Journal of
Engineering Research & Technology (IJERT), 2014, Vol. 3, 2014, Vol.3, pp.866-867.

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 DETECTION OF FAULTS IN BALL BEARING USING VIBRATIONAL ANALYSIS

[10] N. Tanden, A. choudhari, A review of vibration and acoustic measurement

methods for the detection of defects in rolling element bearings.

45