To study methodology and analysis of gearbox

““To Study Methodology and Analysis of Gearbox”To Study Methodology and Analysis of Gearbox”

Internal Guide by:-Mr. Vishal Naik

External Guide by:-Mr. Jitendrakumar Prajapati(9824432906)

Submitted By:-

1. ARVIND RAJPUT(110480119018)2.MILAN PATEL(110480119033)3.AKASH PATEL(110480119013)4.DHARMESH DHANDHUKIYA(110480119073)

Company Profile

CHETNA PUMPS, formerly known as CHETNA PUMPS PVT. LTD.(CPPL) started manufacturing operations since (1989) located in odhav GIDC, Ahmedabad ,Gujarat ,India.

The company is focused in economic of material handling equipment mainly bearing, gearbox, pump lubricant, Oil and water lubricant, conveyor , feeder etc.

In addition company also manufacturing turbine pumps and manufacturing of oil and water lubricant .

Equipment manufacturing by company conforms to validate engineering and IS standards, national and global.

Abstract

On the bases of literature review it can be seen that gear box performance depends on many parameters like gear teeth geometry, gear material, lubricant of gear, loading and working condition. Among of the above parameters the gear teeth geometry, material and lubricant oil are very important factor for incense and decrease the performance of gear system. The gear oil selection processer is very difficult task in industrial application for incense performance of gear system. In lubricant oil the lubricant viscosity is most important factor for selection of gear oil in different industrial application. During working condition the heat is generated, when the two teethes are meshes together. Because of the heat generation inside the gear box, the viscosity of the oil is decrease and that is ultimately changed in oil properties. This change in gear oil property will decrease gear tooth hardness, oil level and speed of gear and increase vibration, noise, wear and power losses. The power loss is due to interaction between the lubricant and the rotating/moving elements. These losses are the sum of squeezing, churning and windage power losses.

Gearbox Maintenance To make sure equipment keep running optimally, gearbox

maintenance is necessary so equipment will be looked after with regular checkups and preventive maintenance performed.

On maintenance programme include:-1. Vibration measurements2. Visual and videoscopic inspection3. Oil analysis4. Non-destructive research5. Wear protection through laser clading

Lubrication and vibration analysis:- Beside gearbox repair, equally important is

discovering the root cause of the gearbox failure in order to avoid unplanned machine down time in the future. To pinpoint equipment failure we perform oil analysis, vibration measurement through visual inspection, for instance examination of abrasive wear performs and gear tooth pitting.

Root cause failure analysis:-

To determine failure root cause we both oil analysis and vibration analysis combined with visual inspections. These diagnostic techniques are usually requried to moniter the condition of plant machinery and to control the cause of machine failure.

Gearbox analysis - Oil analysis :-

In many cases , gear problem result from contaminated or insufficient oil. Oil filter contamination could cause gear tooth damage, sometimes insufficient lubrication causes metal to metal contact with abrasive wear as a result.

Oil analysis provides important information on wear modes and possible gearbox lubrication problems. On the other hand, visual inspections of wear patterns and gear tooth pitting can reveal lubrication problems e.g oil leakage, improper lubricant etc

Vibration analysis:- Vibration analysis is an

effective technique for monitering the condition of gears and determines the root cause of machine failure. We are able to carry out on-site vibration measurements detecting various sorts of gearbox problem:-

Gear damage Alignment Error Imbalance Looseness Bearing defect

Defects in Gear and Gearbox:- Failure Mechanisms

Reason for damage

Name of the process

Result

Mechanical damage

Permanent indentation creating gear meshing

Brinelling Indentation

Crack damage Manufacturing defector stress due to overload

Crack Loss of dimensioning

Wear damage Gradual deterioration

Scuffing -

Insufficient lubrication and contamination

Friction - Accelerate scuffing

Incorrect design Poor choice of bearing type or sizefor required operation

Low load carrying capacity or low speed rating

Thermal instability Large temperature difference builds up

It causes the bearings to lose internal clearance and become pre-loaded which results in increase in heat generation.

Misalignment Manufacturing or setting up errors, elastic deflection of component under load , thermal expansion

Leads to premature pitting, cage wear and finally failure.

Defects in Gear and Gearbox:-

Literature Review

SR NO TITLE INVENTORS

1 Assessing the energy efficiency of gear oils via the FZG test machine

D.J. HargreavesAnton Planitz

Conclusion:-

On the basis of paper results, it was found that the power required running

the best and worst performing oils varied by 14.6%. This represents a

significant reduction in energy requirements and also the potential to

minimize the running costs of industrial machinery. The oils of superior

performance were generally seen to run at lower temperatures. They were

also noted to be of higher cost.


2 Influence of tooth profile and oil formulation on gear power loss

Luis Magalhaes, RamiroMartins, CristianoLocateli, JorgeSeabra

Conclusion:-

On the basis of the paper results, the discussions and conclusions that when gears

311 were replaced by gears 611 the stabilization temperatures decreased. When

lubricated with gear oils M1, P1 and E2, respectively indicating a significant

reduction of the gear friction torque loss. The experimental results also showed that

oils P1 and E2 generated lower stabilization temperatures than the mineral oil M1.

This indicates, they generated lower torque loss and consequently promote a lower

friction coefficient between gear teeth than the mineral oil.


3 Tribological properties of an environmentally adopted universal tractor transmission oil (UTTO) based on vegetable oil

Boris krzan , joze vizintin

Conclusion:-

On the basis of the paper results conclude that Ester based oils show lower friction

coefficient than higher additivated mineral based oils but promote higher wear. Gear

protection properties of the vegetable based oils are better or equivalent than of the mineral

based universal tractor transmission oil. FZG pitting resistance investigations show

significantly better results for the ester based oils, especially for the high oleic sunflower oil

formulation. Laboratory hydraulic system test results show that the high oleic sunflower oil

formulation could match mineral based universal tractor transmission oil for applications

where operating temperatures are reasonable (70 °c in steady state). Investigations in a spur

gear test rig show better thermal oxidative stability for mineral universal tractor transmission

oil compared to the high oleic sunflower universal tractor transmission oil formulation at

constant operating test oil temperature of 80 °c.


4 Power losses at low speed in a gearbox lubricated with wind turbine gear oils with special focus on churning losses

Pedro M.T. Marques, Carlos M.C.G. Fernandes, Ramiro C. Martins, Jorge H.O. Seabra

Conclusion:-

In this study, gear oils were tested for power loss behavior in a two stage

multiplying gearbox, on a back-to-back test rig with recalculating power. The tests

were performed at low input speeds and high input torques. The polyalkylene

glycol oil showed the lowest operating temperatures. poly-α-olefin and mineral +

40% of PAMA performed identically while the Mineral displayed the highest

operating temperatures.


5 The tribological performance of DLC-coated gears lubricated with biodegradable oil in various pinion/gear material combinations

M. Kalin, J. Vizintin

Conclusion:-

On the basis of the work results, concluded that Experimental conditions and by using high quality

biodegradable oil, the contacts of W-DLC/WDLC- coated gears could importantly reduce the oil

temperature and provide satisfactory wear resistance up to A contact pressure of about 1.4 GPa.

Despite the reduced temperature and friction even at higher loads (1.4–1.8 GPa, i.e., FZG stage 10–

12), these conditions cannot be recommended for self-mated coated gears because it will result in high

wear of the coating and lead to premature wear-through of the coating. All the material combinations

that consist of one or two steel gears result in higher oil temperatures than the WDLC/ W-DLC-coated

gears over the whole range of loads and did not vary significantly for the various combinations.


6 Hydraulic losses of a gearbox: CFD analysis and experiments

CarloGorla, FrancoConcl, Karsten Stahl, Bernd-Robert Hohn, Klaus Michaelis, Hansjorg Schultheib, Johann-Paul Stemplinger

Conclusion:-The results of the experiments confirm that the CFD represent valid method to predict power losses. The error in the predictions for the analyzed cases is always lower than 8 % in particular the tip diameter has been changed from 96.5 to 102.5 mm while the tooth width has been changed from 20 to 40 mm.


7 Influence factors on gearbox power loss Bernd-Robert Hohn, Klaus Michaelis and Michael Hinterstoiber

Conclusion:-No load losses can be reduced, especially at low temperatures and Part load conditions when using low viscosity oils with a high viscosity index. This in turn influences the cooling properties in the gear and bearing meshes. Bearing systems can be optimized when using more efficient systems than cross loading arrangements with high preload. Low loss gears can contribute substantially to load dependent power loss reduction in the gear mesh. Besides operating conditions no load gear losses mainly depend on immersion depth in sump lubricated gearboxes as well as on lubricant viscosity. And also conclusions that, in some applications only the simple change to a highly efficient lubricant can save some 20% power loss.


8 An experimental investigation of the influence of the lubricant viscosity and additives on gear wear

Timothy L, Krantz, Ahmet Kahraman

Conclusion:-

The results indicate that the wear rates are strongly related to the viscosity of the

lubricant. Lubricants with larger viscosity result in larger lambda ratios and lower

wear rates.


9 Prediction of overall efficiency in multistage gear trains

James Kuria, John Kihiu

Conclusion:-

On the basis of the paper results finally conclude that overall efficiency of a gear

system is the first step in improving the efficiency of the system. One way to

conduct efficiency improvements is to carry out analysis on the effect of gear

design parameters, lubricant properties and housing arrangement on the efficiency

of the gear system.


10 Investigations on the power losses and thermal effects in gear transmissions

G Koffel, F Ville, C Changenet, P Velex

Conclusion:-

From this experiment and work it is confirmed that tooth friction appears as the main

source of dissipation in low–medium-speed gear transmission. To accurately evaluate

these power losses, it is necessary to develop a thermo mechanical model that includes a

precise description of the tooth contact frictional properties. The lubricant temperatures

at the tooth contacts should also be precisely determined since it controls part of the

dissipation process. Two specific models have been presented and combined, which rely

on the formula for tooth friction and on a thermal network for local temperature

calculations. The theoretical results compare well with the measurements obtained from

an industrial test rig and stress the fact that thermo-mechanical couplings cannot be

ignored in power loss simulations.

Problem Statement

From the literature survey it is seen that the power losses calculation is important for increase the gear performance. The power losses in gear system are depends on types of gear oil and operating condition of gear system. There are number of gear oils are available in the market. But the selection of the gear oil is very difficult task for industries to increase the performance with economy. So my problem statement is “To find out the power losses for different gear oils on operating condition and alternative of it.”

Objective of Work

From problem statement the objective of work is to find out power losses by using industrial gear oils and alternative oil.

For this following steps are needed to be perform:-

1.Modelling of Gearbox2.CFD analysis of gear oil in Anysis

Impact Statement

Improved availability and reliability of primary processAlignment error can be avoidedFewer unplanned maintanceBetter risk and safety managementReduction of repair cost

Questions

THANK YOU

To study methodology and analysis of gearbox

Engineering

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