USING ULTRASONIC FLAW DETECTOR TO CHECK OUT ADEQUATE INTERFERENCE OF RACEWAY OF BEARING OVER THE AXLE WAG-9 ELECTRIC

LOCOMOTIVE
R M GHOTKAR1, D Y SHAHARE2
1 M. Tech Student, Department of Mechanical Engineering, Yeshwantrao Chavan College of Engineering, Nagpur, Maharashtra; 2 Assistance Professor, Department of Mechanical Engineering, Yeshwantrao Chavan College of Engineering, Nagpur, Maharashtra.

Abstract: As part of the development of a new manual Non Destructive Testing (NDT) system combining complementary inspection techniques, an inspection system based on Ultrasonic Flaw Detector for detection of interference between inner raceway of bearing over the railway motor axle. This paper presents the initial study, which includes the UFD experimental setup and the initial results obtained after testing the system on railway inner raceway of bearing over the axle. The oscillating systems used for the production of ultrasound waves should be suitable for working with high frequencies. This means that all oscillating systems with spring and mass separated, which are used for the production of sound in the hearing range, cannot be used to produce ultrasound since we cannot increase their Eigen frequencies above a certain value. The propose work of this project, is to inspect and maintain the adequate interference between inner raceway of motor suspension bearing over the power axle by Ultrasonic Flaw Detector. The angular probe of 510 is to be use for inspect the interference, in this type of instrument diagonally and radials inspection are possible, the angle of probe is to be special design regarding to axle diameter and diagonal distance. Keywords: Ultrasonic flaw detector, interference, bearing, railway axle.

1.

INTRODUCTION

WAG-9 is an electric locomotive engine of Indian railways used to haul specially goods train and is maintained by Ajani Loco shed, Nagpur India. The Loco has six axles in two sets of three frontal and rear wheels. Each of the axles has powered motor since the axle called powered axle. The motor housing is stationary and Axle, Homed mainly at Gomoh, Ajni, Lallaguda, Tughlakabad and Bhilai, it is currently the most powerful locomotive in Indian Railways fleet. It is very similar to the class WAP-7; the only difference being the gear ratio which makes it suitable for heavy freight operations. The ultrasonic testing is based on time-varying deformations or vibrations in materials, which is generally referred to as acoustics. Acoustics is focused on particles that contain many atoms that move in unison to produce a mechanical wave. Ultrasonic test uses the pulse-transit time method with normal beam probes. For this application best results are achieved with probes in composite technique - having a large bandwidth, the sound is transmitted into the face side of the axle by direct contact via a small water gap. In electric freight locomotives two rolling bearings fitted into a housing support the traction motor that is arranged transverse to the direction of travel. The motor rests directly on the wheel set shaft in these two so-called axle suspension roller bearings. When rail axle bearings are operated at high speed, they generate vibrations and noise. The

principal forces, which drive these vibrations, are the time varying nonlinear contact forces, which exist between the various components of the bearings, i.e. the rolling elements, races with the axle and wheel. For investigating the adequate interference of rail axle bearings, a model of the bearing assembly can be considered, in which the outer race of the bearing is fixed in a rigid support and the inner race is fixed rigidly with the shaft. 2. OBJECTIVES Maintain the adequate interference between inner raceway of bearing over the power or motor suspension axle. Develop easy inspection technique. Prevent accident and traffic due to jamming of axle. Readings from the experimental checkout gives the preventive action and save the bearing as well as axle life. LITERATURE SURVEY

3.

[1] A82 1997 Power Transmission Design Bearings allow smooth, low-friction motion between two surfaces loaded against each other. Load is applied to a bearing in either of two directions, or both. Radial loads act at right angles to a bearings axis of rotation. Axial loads are applied parallel to, rather than at right angles to, the bearings axis of rotation. In many situations, bearings must support radial and axial loads simultaneously. In fact, many bearings designed to carry primarily radial loads usually carry some axial load, too. Bearings that support loads

International Journal of Mechanical and Production Engineering (IJMPE) ISSN 2315-4489, Vol-1, Iss-1, 2012 79

Using Ultrasonic Flaw Detector to Check Out Adequate Interference of Raceway of Bearing Over the Axle WAG-9 Electric Locomotive

perpendicular to their axis of rotation are called radial-type. Bearings supporting loads parallel to their axis of rotation are termed thrust bearings. [2] Claus GERKEN, Gnter FUCHS, Wolfgang HANSEN, Heiko SACKENREUTHER, GE Sensing & Inspection Technologies GmbH, Huerth & Alzenau, Germany Automated Ultrasonic Testing System for Railway Axle Automated ultrasonic testing of railway axles during the manufacturing process has become an ever-increasing part of the testing needs in the railway segment, which is a growing portion within the worldwide field of transportation. Due to the high safety requirements railway axles are inspected thoroughly and comprehensive already during the manufacturing process for defects and irregularities. During the past mostly the axles have been inspected manually. The present requirements however ask for inspection already in the production line. This inspection especially deals with irregularities caused by and during the manufacturing process in the axle material. During later train operation the wheel sets are subject to alternating bending stresses, which, over a period of time, could cause rise to fatigue cracks. Unnoticed they cause axle fractures, which in turn, can cause serious accidents. [3] NBC Spherical Roller Bearing Mounting, Dismounting and Maintenance Manual NATIONAL ENGINEERING INDUSTRIES LTD. JAIPUR was founded in the year 1946 as a pioneer industry in the field of bearing manufacturing by the renowned industrialist, late Shri B.M.Birla, under the name of National Bearing Company Ltd. The first bearing was manufactured in 1950 with a modest start of 30 thousand bearings in 19 sizes. The company is now producing nearly 2.2 million bearings per month in over 500 different sizes ranging from 6 mm diameter to 1300 mm diameter and has the capacity to produce bearings upto 2000 mm diameter. At NEI, the development of bearings is a never ending job. With ever increasing activities and grant of industrial licenses for other vital industries and manufacturing of Roller Bearing Axle Boxes for Railway Rolling Stock, Steel Balls, Tapered Roller Bearings, Spindle inserts etc., the name of the company was changed in 1958 to National Engineering Industries Ltd. retaining its original trade mark NBC. [4] Expertise in Bearing Technology and Service for Rail Vehicles Modern rail vehicles combine a high level of traveling comfort economically with low noise disturbance and high performance. Rolling bearings manufactured by Schaeffer Group Industrial in gearboxes, traction motors and axle suspension bearing supports make an important contribution to this. Whether for locomotives, power cars and multiple units or light rail vehicles cylindrical roller bearings have stood the test in the wheel sets of all types of rail vehicles. They are particularly suitable for supporting high radial loads and are usually designed with special internal constructions and polyamide cages for axle box bearing applications.

4.

OUTLINE OF SYSTEM

4.1 Design of Angular Probe Echo of racer : 295mm * 1.81m = 533 mm = 5.3 div. Echo of collar : 314mm * 1.81m = 568 mm = 5.7 div.

The UFD probe are normally flat, std. Dia. is 15 to 20 mm and 2.5 MHz frequency. The material of angular probe is Perpex wedge polymer. When a normal flat probe of 15 to20 mm diameter passing ultrasound wave through (via) angular beam probe of perpex wedge polymer, the longitudinal waves is converted into shear waves by the angle more than 270 , then the shear waves multiply by standard multiplying factor that is 1.81 ( it is the ratio of shear wave and longitudinal wave)

Figure :1

Figure :2

Shear wave / distance trivial by longitudinal wave = 1.81 (Transverse distance or diagonal distance multiply by 1.81. is shows on the ultrasonic display scale)

International Journal of Mechanical and Production Engineering (IJMPE) ISSN 2315-4489, Vol-1, Iss-1, 2012 80

Using Ultrasonic Flaw Detector to Check Out Adequate Interference of Raceway of Bearing Over the Axle WAG-9 Electric Locomotive

4.2 Calibration of Probe Angle There are two methods for calibration of probe 1. 2. I. I. W. Block Standard Step Block

1. I. I. W. Block (International Institute of Welding) I.I.W Block is the angle measuring instrument of ultrasonic probe and its referred to as International Institute of Welding Block. This is very simple instrument and check out accurate angle of the probe. Setup of I. I. W Block These block having a rectangular shape of 100mm * 25mm dimension; curve type profile provided on one end of the block for reflecting wave from the probe, Angular scale printed on of the face on the block is to measured the angle of probe. Working:Ultrasonic probe is very expensive and dedicated member of ultrasonic inspection system, since its calibration is needed for accurate reading and its done by I.I.W Block. The angular probe put on larger face of the block, before that the water film produces between the probe and block for propagating sound waves in proper manner. The ultrasonic sound waves are propagated through the angular probe and acting on the curve profile and reflected it. The emitting waves is collected the probe itself , that place of the probe showing the angle of probe by measuring scale of I.I.W block.

vibration motion exist at the atomic level; however, most are irrelevant to acoustics and ultrasonic testing. Acoustics is focused on particles that contain many atoms that move in unison to produce a mechanical wave. When a material is not stressed in tension or compression beyond its elastic limit, its individual particles perform elastic oscillations. When the particles of a medium are displaced from their equilibrium positions, internal (electrostatic) restoration forces arise. It is these elastic restoring forces between particles, combined with inertia of the particles that leads to the oscillatory motions of the medium. In solids, sound waves can propagate in four principle modes that are based on the way the particles oscillate. Sound can propagate as longitudinal waves, shear waves, surface waves, and in thin materials as plate waves. Longitudinal and shear waves are the two modes of propagation most widely used in ultrasonic testing. The particle movement responsible for the propagation of longitudinal and shear waves is illustrated below. Shear wave is applicable to measure the angle, more than 350 In longitudinal waves, the oscillations occur in the longitudinal direction or the direction of wave propagation. Since compression and ideational forces are active in these waves, they are also called pressure or compression waves. They are also sometimes called density waves because their particle density fluctuates as they move. Compression waves can be generated in liquids, as well as solids because the energy travels through the atomic structure by a series of compressions and expansion (rarefaction) movements. Longitudinal wave is applicable to measure the angle, less than 270. In the transverse or shear wave, the particles oscillate at a right angle or transverse to the direction of propagation. Shear waves require an acoustically solid material for effective propagation, and therefore, are not effectively propagated in materials such as liquids or gasses. Shear waves are relatively weak when compared to longitudinal waves. In fact, shear waves are usually generated in materials using some of the energy from longitudinal waves. Transverse wave is applicable to measured the very low angle, less than 270 and more than 0o 6. 1. PROBLEM IDENTIFICATION Due to the inaccuracy of rail track Thumping accurse and fatigue load acting on bearing inner raceway. Loose bearing raceway damage surface of the axle.

Figure 3. Checking Angle of Probe

5.

WAVE PROPAGATION

Ultrasonic testing is based on time-varying deformations or vibrations in materials, which is generally referred to as acoustics. All material substances are comprised of atoms, which may be forced into vibration motion about their equilibrium positions. Many different patterns of

2.

International Journal of Mechanical and Production Engineering (IJMPE) ISSN 2315-4489, Vol-1, Iss-1, 2012 81

Using Ultrasonic Flaw Detector to Check Out Adequate Interference of Raceway of Bearing Over the Axle WAG-9 Electric Locomotive

3. 4.

Manual or visual inspection are not possible because of bearing is so compact. An assembly time if bearing could not fitted in desired interference limit.

7.

CAUSES OF LOOSE INNER RACEWAY

Increase Rolling Friction Proper quality and quantity of grease maintains minimum rolling friction roller and outer surface of inner races. Any abnormality in the axle box contaminants the grease by metal particles from roller and cage may increase the friction, rising temperature in the axle box. The temperature of inner race also increases become inner race loose. This cause relative motion between race and the journal leading sometimes step down position below the inner race of axle material. Therefore the successful working of inner race is dependent upon the quality and adequacy of grease. Interference Due to normal wear and tear the diameter of the journal is reduced and inner diameter, of inner race become enlarged This may also causes loosening of inner races, if the old inner race is used extensively when more mileage is earned by the locomotive. The axle journal after matching contains matching marks in the form of peaks and valleys. The O.D. Of the journal includes the peak of the machining marks. As per calculation of the inspection staff the measurement interference between journal and inner race may fall within specified limits but considerable proportion of the interference may lost during fitment of inner race or during service by crushing or deformation of the peaks by compressive forces. The loss of interference in such cases loosens inner races on journal. Therefore matching must be subjected to grinding / burnishing which makes surface smooth and skin hardening effect. This is beneficial to retain required interference during service. Surface Film

Bearing and axle assembly is too complicated because of its rigidity, for performing smooth operation the inner raceway and axle are providing interference fit. Interference is done by heating the inner races of bearing in proper amount for thermal expansion, and inserts it in axle also cool it at atmosphere temperature. The tolerance maintained at 0.05 microns. Interference is depending on heating and cooling of the bearing. If heating at very high temperature and the expansion is too more, clearance fit occurs. Also if the cooling treatment is exceed than the desired limit, chance of crack the bearing. Inner raceway of bearing over the axle gets loose before his; life cause of fatigue load arises, like thumping due to rail track, thermal expansion due to continuous running in summer season, if the interference limit fall below 90 to 60 microns then the inner raceway start move around the axle also cuts the axle surface because of bearing material is harder than the axle. The following table shows the interference limits

Interference in microns)

limit(

Causes

90 to 150 microns 90 o 60 microns 150 above microns

Required interference Loose the bearing Crack the bearing

The adulteration of moisture in grease and fretting corrosion near outer edge of plain inner race (PIR) and near inner edge of lip inner race (LIP) may penetrate oxide film between inner race and axle journal. This may cause sliding friction giving sliding action. It is therefore necessary that before fitment of inner race on axle journal the surfaces of both the components should be made smooth and clean and free from dirty surface films. 8. WHY BEARING INNER RACEWAY FAIL

Figure :3

In general, if rolling bearings are used correctly they will survive to their predicted fatigue life. However, they often fail prematurely due to avoidable mistakes. Failure of the rolling bearing can occur for a variety of reasons. Accurate determination of the cause of a bearing failure is must to make suitable recommendations for eliminating the cause. The major factors that singly or in combination may lead

International Journal of Mechanical and Production Engineering (IJMPE) ISSN 2315-4489, Vol-1, Iss-1, 2012 82

Using Ultrasonic Flaw Detector to Check Out Adequate Interference of Raceway of Bearing Over the Axle WAG-9 Electric Locomotive

to premature failure during service include incorrect mounting, excessive loading, inadequate & insufficient lubrication, impact loading, vibrations, contamination, entry of harmful liquids. It is difficult to determine the root cause of some of the premature failures. If all the conditions at the time of failure, and prior to the time of failure are known, including the application, operating conditions and environment, then by studying the nature of failure and its probable causes, the possibility of similar future failures can be reduced. Two or more failure pattern can occur simultaneously and can thus be in competition with one another to reduce the bearing life. Also a pattern of failure that is active for one period in the life of a bearing can lead to or can even be followed by another failure mechanism, which then cause premature failure. Thus in some instances, a single failure pattern will be visible and in other indications of several failure pattern will be evident, making exact determination of root cause difficult. So when more than one bearing failure pattern has been occurred, proper analysis depends on careful examination of failed components. In contrast to fatigue life, this premature failure could be caused by: 1. 2. 3. 4. 5. 9. IN CORRECT FIT IMPROPER MOUNTING IMPROPER HANDLING POOR LUBRICATION EXCESSIVE LOAD PROBLEM FORMULATION

Worst bearing Frame 8 nil

When a normal flat probe of 15 to20 mm diameter passing ultrasound wave through (via) angular beam probe of perpex wedge polymer, the longitudinal waves is converted into shear waves by the angle more than 270 , then the shear waves multiply by standard multiplying factor that is 1.81 ( it is the ratio of shear wave and longitudinal wave) Shear wave / distance trivial by longitudinal wave = 1.81 (Transverse distance or diagonal distance multiply by 1.81. is shows on the ultrasonic display scale)

Inspection Component Distance on UFD

Reading (Echo)Racer 5.3 division

Reading (Echo)collar 5.7 division

9.2 Experimental setup A schematic diagram of a rail axle bearing system is shown in Fig. 1.

9.1 Experimental Readings

Bearing Condition New Bearing Frame 1 Used bearing Frame 2 Frame 3 Frame 4 Frame 5 Frame 6 Frame 7

Reflection Intensity (Interference)

Full

2 3 5 5 3 4
Figure: 4

Checkout wheel bearing inner raceway

International Journal of Mechanical and Production Engineering (IJMPE) ISSN 2315-4489, Vol-1, Iss-1, 2012 83

Using Ultrasonic Flaw Detector to Check Out Adequate Interference of Raceway of Bearing Over the Axle WAG-9 Electric Locomotive

9.3 CAD Model

Frame 4

Reflection Intensity (Interference)

Division(Length)

Figure 5

Poor Interference bearing

Various conditions bearing are check out: These frames shows the interference limit of bearing
Reflection Intensity (Interference)

Frame 4

Frame 1
Reflection Intensity (Interference)

Division(Length) Poor Interference bea ring

Division(Length)

New bearing

Frame 5
Frame 2
Reflection Intensity (Interference)

Reflection Intensity (Interference)

Division(Length)
Division(Length)

Good Interference bearing

Poor Interference bearing

Frame 6
Frame 3
Reflection Intensity (Interference)

Reflection Intensity (Interference)

Division(Length)
Division(Length)

Poor Interference bearing

good Interference bearing

International Journal of Mechanical and Production Engineering (IJMPE) ISSN 2315-4489, Vol-1, Iss-1, 2012 84

Using Ultrasonic Flaw Detector to Check Out Adequate Interference of Raceway of Bearing Over the Axle WAG-9 Electric Locomotive

Frame 7
Reflection Intensity (Interference)

the life of the bearings. Temperature increase due to increased friction is not even considered as a symptom of bearing failure in many bearing analysis texts2 until Stage 3 bearing failure occurs. If temperature is a reliable method of bearing life prediction, why is it ignored until after it's too late? The monitoring of temperatures with thermography has been considered unreliable because so many variables such as ambient temperature, speed, load and runtime all have a pronounced influence on bearing temperature. This article compares identical or near-identical bearings on the same shaft which cancels the effects of these variables because they are common to both bearings. The remaining temperature differences between the two bearings on a common shaft with the same load, can only be the result of friction, an indicator of bearing problems. Perhaps subtle changes are hidden because there are so many variables that can potentially contribute to bearing temperature. In addition to friction, other factors that can contribute to temperature variation are load, speed, ambient environment temperature and runtime duration. If these conditions could be predicted and accounted for accurately, then increases in temperature would reliably indicate bearing problems. In most cases vibration analysis and oil analysis are still the best ways to determine bearing health. Unfortunately, it's not always possible or affordable to use these methods in hostile production environments. Any environments where staff or technicians cannot easily access the machine without taking it offline, or cannot access the machine due to hazardous conditions or inconvenient locations make vibration or oil analysis expensive at best, or even impossible. There are many industries and production environments where bearing failure represents catastrophic loss, yet vibration analysis is not practical. Photographic film and paper manufacturing, chemical processing and metalworking plants are a few examples of industries that depend greatly on bearings, but where bearing accessibility can be a major problem. Most manufacturers have at least some vital equipment in areas that are not easily accessible. 11. ADVANTAGE 4675 * 9.81 = 45.89 kN The basic advantages of ultrasound and ultrasonic instruments are: 1. 2. 3. They are directional and can be easily located They provide early warning of impending mechanical failure Instruments can be used in loud, noisy environments

Division(Length) Poor Interference bearing

Frame 8

Reflection Intensity (Interference)

Division(Length) Worst bearing

Table I: Geometric and Physical Properties used for the Roller Bearings

Mass of rolling element (mj) Mass of the inner race (min) Mass of the outer race (mout) Mass of one axle (maxle) Length over which the Rollers are Actually in Contact Rolling Rearing only (leff) Reaction forces at each contact point

16 kg 7 kg 7 kg 1487 kg 8 cm

10. MONITORING BEARING CONDITION Machine bearings are generally monitored through vibration analysis, oil analysis and/or ultrasound techniques. Through these, it is possible to compare current data to historical data and accurately assess

International Journal of Mechanical and Production Engineering (IJMPE) ISSN 2315-4489, Vol-1, Iss-1, 2012 85

Using Ultrasonic Flaw Detector to Check Out Adequate Interference of Raceway of Bearing Over the Axle WAG-9 Electric Locomotive

Scope Railway Bearing Maintenance This Specification covers the surface finish required on all traction motor suspension bearing axle journals. The surface finish requirement has been shown to be critical to the elimination of suspension bearing failures. Roller Bearing Maintenance used in Indian Railway coaches, with the main consideration of proper mounting, dismounting and preventive maintenance of bearing.

ACKNOWLEDGMENT This paper has been able to attain its objective only because of constant guidance and efforts of my project Guide Prof. D. Y. Shahare from YCCE, Mechanical Department He not only showed us the way but molded my inexperience ideas and gave it to practical outlook. I am thankful to Mr. Chavji from C & M department of Ajani Loco shed. REFERENCES
[1]. FAG OEM und Handel AG The Design of Rolling Bearing Mountings Design Examples covering Machines, Vehicles and Equipment Publ. No. WL 00 200/5 EA PDF 4/8: Rail vehicles Shipbuilding. [2]. NBL Spherical Roller Bearing NBC Spherical Roller Bearing Mounting, Dismounting and Maintenance Manual [3]. Claus GERKEN, Gnter FUCHS, Wolfgang HANSEN, Heiko SACKENREUTHER, GE Sensing & Inspection Technologies GmbH, Huerth & Alzenau, Germany AUTOMATED ULTRASONIC TESTING SYSTEM FOR RAILWAY AXLES [4]. Stuart Hillmansen1 & Roderick A Smith Railway Research Group, Department of Mechanical Engineering, Imperial College London SW7 2AZ, UK ASSESSING FATIGUE CRACK GROWTH IN RAILWAY AXLES [5]. Expertise in Bearing Technology and Service for Rail Vehicles INA and FAG products and services for rail vehicles as [6]. Yukinori Iizuka Highly Efficient Automatic Ultrasonic Flaw Detection System for Weld Seams of UOE Pipes Dr., Senior Research Engineer, Sensing & Control Research Dept., Applied Technology Research Center

12. CONCLUSION: Ultrasound instruments are quite versatile and are ideally suited to predictive/preventive maintenance programs. Their enhanced sensitivity makes them ideally suited to note early stages of bearing failure and especially lubrication conditions. By electronically translating ultrasound emissions down into the audible range, these instruments enable users to hear and recognize when and when not to add lubrication thus preventing over lubrication. In this project work, the effects of radial internal clearance, interference and axle speed of railway axle bearing system have been studied. The railway bearing interference checking problem is completely solved by this project and accepted in railway C & M department.

International Journal of Mechanical and Production Engineering (IJMPE) ISSN 2315-4489, Vol-1, Iss-1, 2012 86