Optimisation of Resonance frequency for maximizing the amplitude

in Envelop Analysis for a Rolling Element Bearing

A Project Report
submitted by

NATTA RAJESH
(ME13B140)

in partial fulfillment of the requirements

for the award of the degrees of

BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING
and
MASTER OF TECHNOLOGY
in
PRODUCT DESIGN

under the guidance of

Dr. Piyush Shakya

DEPARTMENT OF MECHANICAL ENGINEERING

INDIAN INSTITUTE OF TECHNOLOGY MADRAS
CHENNAI - 600036
 Department of Mechanical Engineering
Indian Institute of Technology Madras

Certificate

This is to certify that the project titled " Optimisation of Resonance frequency
for maximizing the amplitude in Envelop Analysis for a Rolling Element Bearing ",
submitted by " NATTA RAJESH (ME13B140)", to the Indian Institute of Technology,
Madras, in partial fulfilment of the requirements for the award of the degree of Master of
Technology in product design, is a bona fide record of project work carried out by him
in Department of Mechanical Engineering, I.I.T. Madras. The contents of this project in
full or in parts have not been submitted to any other institution for an award of any
degree or diploma.

Dr. Piyush Shakya

Project Guide,
Machine Design Section,
Department of Mechanical Engineering,
Indian Institute of Technology, Madras,
Chennai, Tamil Nadu - 600036.

Dr. N Ramesh Babu

Professor & Head of the Department,
Department of Mechanical Engineering,
Indian Institute of Technology, Madras,
Chennai, Tamil Nadu - 600036.

Date: 18th June 2018

Place: Chennai
 Acknowledgements

I would like to start by expressing my sincerest gratitude towards my Project guide

Dr.Piyush Shakya for giving me an opportunity to do project work under his valuable
guidance. He gave me valuable motivation and encouragement throughout my project.
He explained me the basic concepts related to the project and also explained the
methodology to carry out the project in a stepwise manner. He also taught me about
how to present the work as clearly as possible. I am highly indebted for his kind nature
and help in both project work and personal life. It was a great honour and privilege to
work and study under his valuable guidance.

I am grateful to Dr. Bhaskar Ramamurthy, Director of IIT Madras and Dr. Ramesh
Babu.N, Head of Mechanical Engineering Department for providing me the necessary
facilities required for the completion of this project. I also extend my gratitude to all
faculty members of Machine Design Section for their cooperation during my studies.

I am extremely grateful to my parents for what they did for me since from birth. They
always do prayers for my better future. They always guide me in every situation of life.

Finally, my thanks go to all the people who have supported me to complete the project
work directly or indirectly

NATTA RAJESH
 Abstract

Rolling element bearing is the heart of rotating machinery. The Failure of the
Rotating machinery is mostly due to the failure of the bearings. It is very important to
understand the reasons of bearing failure in order to operate the machine in healthy
condition. The failure of the bearings are mostly due to dirt present in the bearings.
There are four types of defects present in a bearing which cause the failure of bearing.
These defects are Inner race defect, Outer race defect, Cage defect, and ball defect.

The aim of this project is to optimise the resonance frequency zone in the
Envelop Spectrum Analysis so that the defects can be detected very fast. In this paper
we are going to discuss about the Envelop analysis and Kurtosis of a vibration signal
and their effects on the different defective types of bearings. The kurtosis indicates the
peak of a distribution curve that the data points have fitted. Optimisation of different
Vibration signals is carried out on MATLAB®. The response of the vibration from the
model is shown in the time domain as well as in frequency domain.
 Table of Contents

Acknowledgements………………………………………………………………………………………………………………...
................................................................................................................................................................ ii
Abstract .................................................................................................................................................. ii
Chapter 1 ............................................................................................................................................... 1
INTRODUCTION................................................................................................................................. 1
1.1 Objective ....................................................................................................................................... 2
1.2 Literature Review.......................................................................................................................... 2
Chapter 2 ................................................................................................................................................. 3
Bearing Terminology ............................................................................................................................ 3
2.1 Defects in Bearings ....................................................................................................................... 3
2.2 Bearing Fault Frequencies ............................................................................................................ 4
Chapter 3 ............................................................................................................................................... 5
Extraction of Parameters ..................................................................................................................... 5
3.1 Time Domain Parameters.............................................................................................................. 5
3.2 Frequency Domain Parameters ..................................................................................................... 5
3.2.1 Discrete Fourier Transform ................................................................................................ 6
3.2.2 Envelop Analysis..................................................................................................................... 6
Chapter 4 ............................................................................................................................................... 7
Results .................................................................................................................................................... 7
4.1 Envelop Analysis .......................................................................................................................... 7
4.1.1 Inner race defect ..................................................................................................................... 8
4.1.2 Outer race defect ................................................................................................................ 11
Chapter 5 ............................................................................................................................................. 17
Conclusion and Future Scope ............................................................................................................ 17
5.1 Conclusion .................................................................................................................................. 17
5.2 Future Scope ............................................................................................................................... 17
 List of Figures

Figure 1. 1 Parts of Rolling Element Bearing [1] ................................................................................................. 1

Figure 2. 1 Faults in Rolling Element Bearing ...................................................................................................... 3
Figure 4. 1 Time domain signal for Inner race defect........................................................................................ 8
Figure 4. 2 Vibration Signal in Frequency Domain ............................................................................................. 8
Figure 4. 3 Zoomed Vibration Signal in Frequency Domain .......................................................................... 9
Figure 4. 4 Envelope Signal of the inner race defect ....................................................................................... 10
Figure 4. 5 Envelope Spectrum of the inner race defect................................................................................ 11
Figure 4. 6 Envelope Spectrum of outer race defect ....................................................................................... 11
Figure 4. 7 Comparison of Kurtosis values of different type of defects .................................................. 12
Figure 4. 8 Kurtogram of outer race defect signal ........................................................................................... 13
Figure 4.9 Spectral kurtosis of outer race defect signal ………………………………………………………….14

Figure 4.10 Envelop of the outer race defect after passed through band pass filter …………..15

Figure 4.11 Envelope Spectrum of outer race defect …………………………………………………………16

 List of Tables
Table 4.1 Bearing Characteristics ………………………………………………………………………………………7
 Abbreviations

BPFI Ball Pass Inner Frequency

BPFO Ball Pass Outer Frequency
BSF Ball Spin Frequency
FTF Fundamental Train Frequency
Pd Pitch diameter of the bearing
Bd Ball diameter of the bearing
φ Contact angle
n Number of rolling element
f Rotations frequency of the shaft
Chapter 1
INTRODUCTION

Rolling element bearing is a machine element, which guides the components which are
having relative motion with each other and reduces the friction between them. This is the
most common type of bearing which is used in the industry. The industries which frequently
used this bearing are aerospace, mining, construction railway, steel and textile. The proper
function of the bearing is very important for a machinery. Any types of failures or damage in
the bearings cause a machinery breakdown which consequently becomes the reason for
various industrial losses and it also endanger the lives of people in some cases.

Figure 1. 1 Parts of Rolling Element Bearing [1]

Defects are classified into four categories in bearings. These defects are inner race defect,
outer race defect, ball defect and cage defect. whenever the defective component of the
bearing either outer race, inner race or rolling element of bearing comes in contact with the
corresponding mating part it generates the vibration signal. By observing the vibration signal
due to the defect the type of failure present in the Rolling element bearing can be
identified. There are lots of literature present regarding Envelope Detection, but we can still
optimise this process using optimisation algorithms.

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The choice of a bearing as a system for vibration Analysis is chosen because of bearing is an
essential component of almost all forms of rotating machineries. Also it is that kind of
machine element, whose failure without forewarning can damage the system to
unrepairable levels. The production losses that are occurred due to improper maintenance
of the machinery due to failure of the bearings are much higher compared to the cost of the
bearing.

1.1 Objective
The main Objectives of the project are
1. To analyse optimization algorithms like Kurtosis, ant colony optimization, particle
swarm optimisation or artificial bee colony algorithm for the optimisation of
resonance frequency zone.
2. To create/modify an algorithm for finding the desired frequency to detect the
bearing faults using simulation in MATLAB.
Simple time or frequency domain analysis of vibration of raw signal unable to identify
defects in the bearings. Many research scholars tried to solve this case using various
processes like Spectral Kurtosis (Antoni, 2007).Wavelets are used for detection of faults in
the bearing.

1.2 Literature Review

From the Industrial side, research scholars pays a lot of attention to the bearings due to
their importance in rotating machinery. In addition, majority of the rotating machinery
breakdown is due to the failure of bearings. A lot of research works have concluded that
42% of machine breakdown are due to bearing failure problems. Major failure percentage is
due to dirt struck in the bearings.

The vibration response produced due to the defect present on the inner race of the rolling
element bearing which is kept under the constant application of radial load was developed
by McFadden [1] using impulse model. In this model, the force generated due to the point
defect was modelled by taking infinite series impulses having equal magnitude. The physical
properties of the bearing are not included in this model.

The effect of noise on the vibration of the signal in the time and frequency domain
is described in [7].The presence of noise reduces the quality of the signal generated from
different types of defects.

2
Chapter 2
Bearing Terminology

The important machine components like bearings, gear etc. failed during its runtime, it not
only affects the performance of the system but also causes it to Breakdown. The importance
of geometrical dimensions of the bearing and the kinematics involving in it are very essential
for envelop analysis as it helps to find out speed of the bearing elements with respect to one
another. These frequencies help in extracting many of the
parameters.

Figure 2. 1 Defects in Rolling Element Bearing

2.1 Defects in Bearings

From a vibration standpoint, any area of the bearing contacting surfaces that are not
smooth, stiff or stable can emit energy losses in a measurable form. A fault is most often
degradation of the bearing raceways from fatigue. The fatigue will first arrive in the form of
small pits on the surface of the steel. These pits will gradually propagate into larger surface
areas known as spalling. Other forms of faults include true bearing manufacturer’s defects,
poor steel quality, excessive looseness, and effects from contamination [2].

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2.2 Bearing Fault Frequencies

Bearing fault frequencies also referred as defect frequency, are simply harmonics that
coincide with recurring and consistent impacts between two bearing surface. The harmonic
is simply an rotational speed of the prime rotating body. If bearing surfaces are smooth,
then there are no amplitudes from the energy loss of a collision. However, as a bearing
begins to fatigue or fails then imperfections on contacting surfaces create collisions which
result in an amplitude emission of energy. The frequency allows the user to identify the
component that contributes most to uneven operation. If component frequencies are
known, then the user can look for amplitudes across the vibration spectrum that align with
component frequencies. The user can determine the source of the problem once the
disrupting harmonic is matched to the predicted component frequency. As shown in Fig 2.1,
there are four types of defects, which generates vibration frequencies that can be related to
the different components of a bearing.
The Bearing Characteristic defects are calculated from the following Equations

Fundamental Train Frequency

B
FTF = f/2(1 − Pd cosφ) (2.2.1)
d

Ball pass Frequency Outer Race

f B
BPFO = (n/2)(60)(1 − Pd cosφ) (2.2.2)
d

Ball pass Frequency Inner Race

f B
BPFI = (n/2)(60)(1 + Pd cosφ) (2.2.3)
d

Ball Spin Frequency Rolling Element

P f B 2
BSF = (2Bd ) (60) [1 − (Pd ) cos2 φ] (2.2.4)
d d

Where,
n = Number of Rolling element Bearings
f = Rotations frequency of the shaft
φ = Contact angle
Pd = Pitch diameter of the bearing
Bd = Ball diameter of the bearing

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Chapter 3
Extraction of Parameters
The parameters are extracted from the input data collected is mapped in such a way that it
will be able to indicate system’s condition. This mapping of input data can be done by using
various signal processing techniques. Extracted parameters are used as input for the
optimisation process for finding optimal solution.

In this project work, the input vibration data is processed using following techniques:
1. Time Domain Approach
2. Frequency Domain Approach

3.1 Time Domain Approach

It is the simplest and easiest approach to process the input vibration data. In this approach,
Vibration analysis of the dataset is done as time function . They quickly provide an overall
understanding of the vibration level. Root Mean Square value tells about the energy level of
the vibration signal. Peak factor is the difference between positive peak and the negative
peak. Crest factor gives an idea about nature of the vibration signal. It is the ratio of the
peak factor to the RMS value of a given signal. Skewness is another variable which shows
distributions of data points on either side of the mean i.e. whether the majority of the data
points are smaller or greater than the mean value. The kurtosis indicates the peakness of a
distribution curve that the data points fitted. As the defect reaching an final state of
degradation, value of kurtosis goes on decreasing.

3.2 Frequency Domain Analysis

The frequency domain refers to the display or analysis of the vibration data based on
the frequency. The striking of the defect to contact surfaces in the rolling element bearings
generates pulses of very short duration. These short duration pulses then excites the natural
frequency of the various bearing parts. This creates an increase in level of vibration energy
for that short duration of time. Bearing characteristic fault frequencies are used to extract
the parameters. At these fault frequencies due periodic impacts of defect, there may be a
peak value of amplitude. These peak values at that fault frequencies are extracted from
each dataset as a prognostic parameter.

In frequency domain analysis following two techniques are used:

1. Discrete Fourier Transform
2. High Frequency Resonance Technique

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3.2.1 Fourier Transform

Discrete Fourier Transform (DFT) is the most basic and well-known method in frequency
domain analysis. DFT can able to detect the location of the fault. Hence, it is widely used in
diagnosis of machinery fault as basic frequency domain technique. In this technique, there is
no time dependency and also this approach assumes that the signal is stationary in nature
all the time. The vibration energies which are defined as sum of the squares of amplitudes
are centered at some specific frequencies over some frequency bands.

3.2.2 Envelop Analysis

Envelope analysis or High Frequency Resonance Technique (HFRT) is a popular frequency

domain technique used to detect faults in rolling element bearings. This method is also
known by various names such as amplitude demodulation, demodulated resonance analysis
and narrow band envelope analysis. HFRT is the technique which is able to recognise the
periodic impulses from the modulated random noise produced due to defects in a rolling
element bearing. This process of extracting periodic impulses is also possible even if the
data is contaminated by the other vibrations produced from the machine or if the energy
level vibration data is very low. In HFRT analysis, due to periodic impacts of fault of
particular rolling element, it shows a peak at that particular fault frequency corresponding
to that fault.

The process of HFRT is carried out in following steps:

STEP 1 - Calculate the centre frequency and bandwidth of the signal,

STEP 2 - Filter the signal with bandpass filter,
STEP 3 - Get a envelope of a filtered signal,
STEP 4 - Calculate the envelope spectrum,
STEP 5 - Finally, extract parameters at defect frequencies from spectrum.

The centre frequency and the bandwidth of each data set were calculated using the fast
kurtogram, an algorithm proposed by Antoni[7]. An eight-level fast kurtogram program code
was used for processing all the datasets. By using these values of centre frequency and
bandwidth; frequency band is decided for bandpass filter used for filtering the raw input
data[5]. Hilbert transform is used for getting envelope of the filter signal. FFT is used to
obtain envelope spectrum of the envelope. In envelope spectrum, periodic impacts show up
as a peak (with some harmonics) at the characteristics defect frequency corresponding to
the faulty bearing element.

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Chapter 4
Results
In this chapter, various results obtained from the Envelop Analysis and Kurtosis are
Explained .The time domain and frequency domain characteristics of inner race defect,
outer race defect and ball defect of the rolling element bearing are shown by the help of the
plot obtained from MATLAB.

4.1 Envelop Analysis

The geometrical dimensions of the bearing are not required for the impulse model. But,
from the geometry of the bearings; fault frequencies (FTF, BPFI, BPFO & BSF) are calculated
by using the equations 2.2.1 - 2.2.4.

Bearing Data Collection

Bearing vibration data was obtained from the MFPT bearing data set available at
data-acoustics.There were measurement of three bearing condition, i.e. normal bearing,
faulty innerrace bearing, and faulty outerrace bearing. The bearing data were as follow

The vibration measurement was conducted for three operating conditions:

1. Baseline – no fault, sampling rate of 97,656 Hz, a load of 270 lbs, and record length
of 6 seconds.
2. Outer race fault with the same load of 270 lbs, the sampling rate of 97,656 Hz, and
record length of 6 seconds and outer race fault with variable load, the sampling rate
of 48,828 Hz, and record length of 3 seconds.
3. Inner race fault with variable load, the sampling rate of 48,828, and record length of
3 seconds.

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4.1.1 Inner race defect

Figure 4.1 represents the vibration signal of the raw inner race defect data in time domain.
From the figure it is evident that inner race fault signal has significantly larger impulsives

Figure 4. 1 Time domain signal - Inner race defect

Figure 4. 2 Vibration Signal in Frequency Domain

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The above Figure 4.2 describes the distribution of energy of the waveform (Power
Spectrum) among its different frequency components.

Figure 4. 3 Zoomed Vibration Signal in Frequency Domain

In Figure 4.2 we are unable to interpret between power spectrum and BPFI and its
frequencies. From Figure 4.3 there is no pattern visible at BPFI and its harmonics. From this
we can conclude that frequency analysis on raw signal is useless.

9
 Figure 4. 4 Envelope Signal of the inner race defect

From the time-domain data of the vibration signal, we can observe that BPFI (118.75 Hz)
and main frequency of modulation which is about 1/0.09 Hz ~ 111 Hz. This Clearly Shows
that the bearing has inner defect.

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 Figure 4. 5 Envelope Spectrum of the inner race defect

From the above Graph it is evident that the most of the Energy is concentrated at Ball Pass
frequency Inner race (BPFI) and its harmonic frequencies.

4.1.2 Outer race defect

Figure 4. 6 Envelope Spectrum of outer race defect

In the above graph of Outer race defect signal, we are unable to differentiate between the
BPFO Harmonics and the peak amplitude of the Vibration Signal

11
 Figure 4. 7 Comparison of Kurtosis values of different type of defects

From the above figures it is evident that inner race defect signal has larger impulsives
where the spectrum analysis capture defect signature effectively. In case of outer race
defect signal the amplitude modulation at BPFO is noticeable but the normal signal doesn’t
show any amplitude modulation.

12
4.1.2a Kurtogram and spectral kurtosis

Kurtogram and spectral kurtosis calculate kurtosis within the frequency bands. These are the
powerful tools to locate frequency band that has highest kurtosis. After locating the
frequency band with the highest kurtosis a band pass filter passed to the raw signal to get a
more impulsive signal for envelope spectrum analysis of outer bearing defects. The below
kurtogram has the center frequency at 2.67 kHz with a 0.763 kHz bandwidth has the highest
kurtosis value 2.71.

Figure 4. 8 Kurtogram of outer race defect signal

13
To compute the spectral kurtosis we need to use optimal window suggested by kurtogram.
High values of spectral kurtosis indicates higher value of power at the corresponding
frequency and also a useful tool to locate non-stationary vibrations of the signal.

Figure 4.9 Spectral kurtosis of outer race defect signal

14
Filter the signal through band pass filter with the obtained center frequency and bandwidth, the value
of the kurtosis of the signal is increased and the modulated amplitude of the outer race fault can be
obtained.

Figure 4.10 Envelop of the outer race defect after passed through band pass filter

15
From the Figure 4.11 it is evident that the most of the Energy is concentrated at Ball Pass
frequency outer race (BPFO) and its harmonic frequencies.

Figure 4.11: Envelope Spectrum of outer race defect

16
Chapter 5

Conclusion and Future Scope

5.1 Conclusion

The time domain and frequency domain signal are plotted for both outer race, inner race
and their respective Envelops of the signal and for detecting the faults in bearing we use
envelope spectrum. In the case of the outer race defect by using kurtogram and spectral
kurtosis we are able to successfully obtain required envelope spectrum of the bearings.

5.2 Future Scope

Modelling of single point as well as multi point defect in the rolling element will
be the main area of interest in Rolling element bearing in the future. The effect of different
shapes of defects in the rolling element may also be investigated
.

17
BIBILOGRAPHY
[1]P.D.Mcfadden,J.D.Smith "Model for the Vibration produced by a single point defect in
rolling element bearing. "Journal of Sound and Vibration 1984:96(1) 69-82
[2]T.A.Harris "Rolling Bearing Analysis." 4th edition,John Wiley & Sons,Inc,2001
[3] R.B.Randall “Vibration Based condition monitoring.” 1st edition,John Wiley &
Sons,Ltd,Chichester,United Kingdom, 2011
[4] M.S.Patil,Jose Mathew,P.K.Rajendrakumar,Sandeep Desai “A theoretical model to
predict the effect of localized defect on vibrations associated with ball Bearing."
International journal of Mechanical science 52(2010) 1193-1201
[5] Lingli Cui,Xue Chen,Shujan Chen “Dynamic Modelling and analysis of local fault of
Rolling Element Bearing" Advances in Mechanical engineering,Article Id 262351
[6] C.Mishra,A.K.Samantaray,G.Chakraborty "Ball Bearing defect models: A study of
simulated and experimental fault signatures."Journal of Sound and Vibration 400(2017) 86-
112
[7] Piyush Shakya,Ashish K Darpe,Makarand S Kulkarni "Bearing Damage Classification
using instantaneous energy density "Journal of Vibration and control
[8] N.Sawalhi,R.B.Randall “Simulating gear and bearing interactions in the presence of
faults:part 1.The combined gear bearing dynamic model and the simulation of localised
bearing faults" Mechanical system and signal processing 22 (2008) 1924-1951.
[9] Sidra Khanam,J.K.Dutt,N.Tondon “Impact force based model for bearing local fault
identification" Journal of vibration and acoustics
[10] I. Howard, “A Review of rolling element bearing vibration "detection, diagnosis and
prognosis." DSTO Aeronautical and Maritime Research Laboratory, GPO Box 4331,
October 1994.

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