Identification Of Surface And Sub-Surface Defects In Gear By Using Thermographic Technique

Nurul Hilwa , Mohd Zini (2012) Identification Of Surface And Sub-Surface Defects In Gear By Using Thermographic Technique. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Gear is one of the most common components used in machine. Gear failure is usually associated with temperature. To estimate the life expectancy of gear, there are a few factors to be considered such as loads, helical angle, speed, gear face width, gear surface roughness, force and lubrication properties. This project is conducted to see the relation between temperature and early gear failure. The estimation of gear life expectancy by using a comparison between the theoretical calculation for helical gear with pitting at 1000 rpm speed and experimental result obtained from the operation of a gear test rig is discussed. For the experiment, three load weights are used; 15 kg, 30 kg and 35 kg for the operating duration of 60 hours. Both result from theoretical and experimental is based on thermal analysis. The calculation obtained based on BS ISO 6336-2 result in the theoretical life expectancy of gear with15 kg load of 23 hours, 30 kg of load weight at 16 hours while for gear with 35 kg load at 15 hours. The experiment conducted showed insignificance temperature changes even though the highest temperature recorded is 38°C and the lowest temperature at 29°C. The experiment result shows that at 15 kg of load weight, damage started to occur at the 85th hour while at 30 kg load, gear damage started at 60th hour. For the 35 kg of load weight, the time where damage started to occur is at 120th hour. Due to insignificance temperature changes, thermal analysis can be disregard when involving new and barely worn gear.

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