Abstract: Journal bearings used in IC engines are prone to premature
failures and are likely to fail earlier than the rated life due to
highly impulsive and unstable operating conditions and frequent
starts/stops. Vibration signature extraction and wear debris analysis
techniques are prevalent in industry for condition monitoring of
rotary machinery. However, both techniques involve a great deal of
technical expertise, time, and cost. Limited literature is available on
the application of these techniques for fault detection in reciprocating
machinery, due to the complex nature of impact forces that
confounds the extraction of fault signals for vibration-based analysis
and wear prediction. In present study, a simulation model was developed to investigate
the bearing wear behaviour, resulting because of different operating
conditions, to complement the vibration analysis. In current
simulation, the dynamics of the engine was established first, based on
which the hydrodynamic journal bearing forces were evaluated by
numerical solution of the Reynold’s equation. In addition, the
essential outputs of interest in this study, critical to determine wear
rates are the tangential velocity and oil film thickness between the
journals and bearing sleeve, which if not maintained appropriately,
have a detrimental effect on the bearing performance. Archard’s wear prediction model was used in the simulation to
calculate the wear rate of bearings with specific location information
as all determinative parameters were obtained with reference to crank
rotation. Oil film thickness obtained from the model was used as a
criterion to determine if the lubrication is sufficient to prevent contact
between the journal and bearing thus causing accelerated wear. A
limiting value of 1 μm was used as the minimum oil film thickness
needed to prevent contact. The increased wear rate with growing
severity of operating conditions is analogous and comparable to the
rise in amplitude of the squared envelope of the referenced vibration
signals. Thus on one hand, the developed model demonstrated its
capability to explain wear behaviour and on the other hand it also
helps to establish a co-relation between wear based and vibration
based analysis. Therefore, the model provides a cost effective and
quick approach to predict the impending wear in IC engine bearings
under various operating conditions.
Abstract: Erosion and abrasion are wear mechanisms reducing
the lifetime of machine elements like valves, pump and pipe systems.
Both wear mechanisms are acting at the same time, causing a
“Synergy” effect, which leads to a rapid damage of the surface.
Different parameters are effective on erosive abrasive wear rate. In
this study effect of particle impact angle on wear rate and wear
mechanism of ductile and brittle materials was investigated. A new
slurry pot was designed for experimental investigation. As abrasive
particle, silica sand was used. Particle size was ranking between 200-
500 μm. All tests were carried out in a sand-water mixture of 20%
concentration for four hours. Impact velocities of the particles were
4.76 m/s. As ductile material steel St 37 with Vickers Hardness
Number (VHN) of 245 and quenched St 37 with 510 VHN was used
as brittle material. After wear tests, morphology of the eroded
surfaces were investigated for better understanding of the wear
mechanisms acting at different impact angles by using Scanning
Electron Microscope. The results indicated that wear rate of ductile
material was higher than brittle material. Maximum wear rate was
observed by ductile material at a particle impact angle of 300 and
decreased further by an increase in attack angle. Maximum wear rate
by brittle materials was by impact angle of 450 and decreased further
up to 900. Ploughing was the dominant wear mechanism by ductile
material. Microcracks on the surface were detected by ductile
materials, which are nucleation centers for crater formation. Number
of craters decreased and depth of craters increased by ductile
materials by attack angle higher than 300. Deformation wear
mechanism was observed by brittle materials. Number and depth of
pits decreased by brittle materials by impact angles higher than 450.
At the end it is concluded that wear rate could not be directly related
to impact angle of particles due to the different reaction of ductile and
brittle materials.
Abstract: The present work compares the performance of three
turbulence modeling approach (based on the two-equation k -ε
model) in predicting erosive wear in multi-size dense slurry flow
through rotating channel. All three turbulence models include
rotation modification to the production term in the turbulent kineticenergy
equation. The two-phase flow field obtained numerically
using Galerkin finite element methodology relates the local flow
velocity and concentration to the wear rate via a suitable wear model.
The wear models for both sliding wear and impact wear mechanisms
account for the particle size dependence. Results of predicted wear
rates using the three turbulence models are compared for a large
number of cases spanning such operating parameters as rotation rate,
solids concentration, flow rate, particle size distribution and so forth.
The root-mean-square error between FE-generated data and the
correlation between maximum wear rate and the operating
parameters is found less than 2.5% for all the three models.