Cause analysis and countermeasure on premature failure of a driven gear for the high-speed train

Pan, An-Xia; Yang, Zhen‐Guo

doi:10.1016/j.engfailanal.2022.106487

Cited by 10 publications

(6 citation statements)

References 26 publications

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“…To illustrate the effectiveness of appropriately selecting the K-value on fault classification, an index representing the capacity for identification (𝐶 ) of different rail conditions was calculated. The index could be described as a subtraction of the maximum and minimum differences from the mean value of entropy [10], as given in Equation (19).…”

Section: Results Analysismentioning

confidence: 99%

“…The {Ratio} i defined in Equation (10), represents the relationship between each subsignal and the original signal.…”

Section: Ivmd-svdmentioning

confidence: 99%

“…In this paper, acoustic inspection is a non-invasive technique that can be used widely and provides accurate results. Acoustic techniques have been used in modern railway inspection, but only in limited applications, such as bearing and gearbox monitoring, in which there has been rapid development in recent years due to the capabilities and effectiveness of acoustic techniques in detecting bearing and gearbox faults in the early stages [8][9][10]. The sound generated from wheelsets passing through rail discontinuities, such as crossing noses and insulted rail joints (IRJs), can be related to their structural performances, which can potentially be used in fault detection.…”

Section: Introductionmentioning

confidence: 99%

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An Improved VMD Method for Use with Acoustic Impact Response Signals to Detect Corrosion at the Underside of Railway Tracks

Yang

Stewart

et al. 2023

Applied Sciences

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Variational Mode Decomposition (VMD) is widely used for inspection purposes. The initial parameters are usually set manually, which is a limitation of this technique. In this paper, a method to automatically select these parameters through a combination of Singular Value Decomposition (SVD) and Improved-VMD (IVMD) is proposed. VMD is applied multiple times with a varying K-value parameter. The original signal and its sub-signals arising from VMD decomposition are all subjected to SVD. An index representing the relevance between sub-signals and the original signal is obtained by comparing eigenvalues, which are calculated by SVD. The result shows the effectiveness of VMD with different initial K-value parameters. SVD is then further applied to the VMD result for the selected K-value parameter to obtain Shannon entropy, which can be used in the detection and classification of corrosion on the underside of the rail. Comparing with current energy-based methods, the Shannon entropy obtained by IVMD–SVD has the advantage of reducing environmental interference to obtain more uniform energy results. The proposed method can improve the effectiveness of VMD for the impact response signal. The classification of underside corrosion of rails can be realised according to the results obtained from the proposed method.

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Section: Results Analysismentioning

confidence: 99%

“…The {Ratio} i defined in Equation (10), represents the relationship between each subsignal and the original signal.…”

Section: Ivmd-svdmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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An Improved VMD Method for Use with Acoustic Impact Response Signals to Detect Corrosion at the Underside of Railway Tracks

Yang

Stewart

et al. 2023

Applied Sciences

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“…The production of gears using casting methods is not an easy technological process when considering the need to ensure that the elements being manufactured display sufficient resistance to certain operational factors [ 2 , 3 , 4 , 5 ] such as the abrasive impact of oil contaminant particles and variable dynamic forces [ 6 , 7 , 8 , 9 ]. The gears for mining applications, used in lightweight conveyors, are exposed to variable external loads and internal excitation caused by, among other factors, stiffness fluctuations and manufacturing errors [ 10 , 11 ].…”

Section: Introductionmentioning

confidence: 99%

Abrasive Wear Resistance of Ultrafine Ausferritic Ductile Iron Intended for the Manufacture of Gears for Mining Machinery

et al. 2023

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The purpose of this study was to experimentally determine the abrasion wear properties of ausferritic ductile iron austempered at 250 °C in order to obtain cast iron of class EN-GJS-1400-1. It has been found that such a cast iron grade makes it possible to create structures for material conveyors used for short-distance transport purposes, required to perform in terms of abrasion resistance under extreme conditions. The wear tests addressed in the paper were conducted at a ring-on-ring type of test rig. The test samples were examined under the conditions of slide mating, where the main destructive process was surface microcutting via loose corundum grains. The mass loss of the examined samples was measured as a parameter characteristic of the wear. The volume loss values thus obtained were plotted as a function of initial hardness. Based on these results, it has been found that prolonged heat treatment (of more than 6 h) causes only an insignificant increase in the resistance to abrasive wear.

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“…Например, на этапе изготовления это могут быть некачественный исходный материал, нарушения технологий механической и термической обработок, нанесения покрытий и др. [7][8][9]. В связи с указанной многофакторностью и высокой ответственностью за результат метало-графическую экспертизу в большинстве случаев поручают проводить специализированным аккредитованным организациям, имеющим в своем распоряжении квалифицированных аттестованных специалистов, поверенное испытательное и современное исследовательское оборудование, а также нормативную документацию (методики), регламентирующую процедуры проведения испытаний и исследований.…”

Section: Introductionunclassified

Metallographic examination as the feedback between product quality and manufacturing

Merson,

Karavanova,

Klimanov

2022

FMT

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Despite the increasing automation of the process of designing and manufacturing metal products, their failure remains a common phenomenon. The metallographic examination is appointed, which can only be carried out at a proper level by the specialized accredited organizations to identify the causes of such incidents. A metallographic examination is a tool that acts as feedback between the output quality of products and the entire chain of numerous operations during production. The purpose of this work is, using a practical example, to demonstrate the possibility and special significance of the conclusions of the metallographic examination for the development of the product manufacturing technology. Using the high-speed plasma spraying method, the authors applied the NiCrBSi coating to the surface of the locomotive wheel pair axle to increase its wear resistance. The life bench tests of the axle revealed the main fatigue crack, the tests were stopped, and the axle was artificially broken completely. The analysis of metal quality, including chemical composition, mechanical properties (strength, ductility, and impact hardness), microstructure, metal purity according to the non-metallic inclusions, and parameters of a surface layer hardened by rolling, showed its full compliance with the regulatory documentation. The thickness and hardness parameters of the NiCrBSi coating also corresponded to the declared ones. According to the fractographic analysis, the fatigue fracture was initiated at multiple points, which was a characteristic sign of a common objective reason for the insufficient strength of a product not associated with some random factor. The metallographic examination identified that the main reason for the failure of a wheelset axle is the coating's insufficient fatigue strength. The numerous fatigue microcracks that originated in the coating grew into the base metal and led to the fatigue macrocracks formation at different height levels. The merging of these cracks led to widespread fatigue fracture surface formation.

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Cause analysis and countermeasure on premature failure of a driven gear for the high-speed train

Cited by 10 publications

References 26 publications

An Improved VMD Method for Use with Acoustic Impact Response Signals to Detect Corrosion at the Underside of Railway Tracks

An Improved VMD Method for Use with Acoustic Impact Response Signals to Detect Corrosion at the Underside of Railway Tracks

Abrasive Wear Resistance of Ultrafine Ausferritic Ductile Iron Intended for the Manufacture of Gears for Mining Machinery

Metallographic examination as the feedback between product quality and manufacturing

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