Gear Failure Analysis And Health Monitoring Plan On The Mechanical Component Of An Amusement Park Equipment

Mansor, Muhammad Hilmi (2020) Gear Failure Analysis And Health Monitoring Plan On The Mechanical Component Of An Amusement Park Equipment. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Gears are one of the most important mechanical component in machinery applications. An unexpected gear failure in mechanical equipment can cause a higher downtime. Research has shown that the failure and breakage of the gear is influenced by different type of initiator such as poor maintenance. The aimed for this study is to investigate the failure mode and develop the monitoring plan of the gear. The gear failure is analysed using Finite Element Analysis (FEA). The stress distribution of the gear during contact has been analysed under three different test conditions which is load, pitch circular (teeth size) and pitch diameter. The load values are 500 kg, 700 kg and 1100 kg and pitch circular with different size of teeth; Set 1(2 mm×6.5 mm and 2 mm×7 mm) Set 2(4 mm× 8.5 mm and 4 mm×9 mm) and Set 3 (1 mm×4.5 mm and 1 mm× 5 mm). For the pitch diameter, the load are tested with different diameter of pinion and driven gear which are; Diameter 60 mm and diameter 90 mm;, Diameter 65 mm and diameter 110 mm; and Diameter 100 mm and diameter 150 mm. From the FEA results, it is found that the higher the load given, the higher the stress concentration on the contact surface. The stress increases varies with load due to low percentage of lubricant use thus increase the surface contact of the gear. The rotational gear increases force distribute along the gear mechanism thus increases the stress to the contact surface of gear. Therefore it is recommended that the amusement park gives a proper maintenance of the gear. This mechanical component needs to be checked regularly every 6 months and major check-up can be carried out every 3 years. A correct lubrication type for gear and track need to be used based on the original equipment manufacturer specification.

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