Alexandria University

Faculty of Engineering
Production Engineering Department
Third Year
PE363- Theory & Design of M/C Tools -1
Part I Theory of Vibrations

Fault Diagnostics
Report on Fault Diagnostics in Machine Tools using Vibration
With Practical Case Studies
Presented By

Name

Seat #

Mohamed Emad Abdullah

106

Mohamed Emad Mohamed

107

Mohamed Fouad Saber

108

Mohamed Magdy Ahmed

109

Mohamed Mohsen El-Sayed

110

Mohmed Mohamed Elsyaed

111

Mohmamed Mahmoud El-Sayed

112

Mohamed Mahmoud Mohamed

113

Mohamed Mostafa Ahmed

114

Mohamed Mostafa Abd El-Razaq

116

Table of Contents
Table of Figures ............................................................................................................................................. 1
Introduction .................................................................................................................................................. 2
Maintenance Engineering ............................................................................................................................. 2
Preventive Maintenance ........................................................................................................................... 2
Predictive Maintenance ............................................................................................................................ 2
Unscheduled Maintenance ....................................................................................................................... 2
Why Make Condition Monitoring ................................................................................................................. 3
Fault Diagnostics ........................................................................................................................................... 3
Using Spectrum in Fault Diagnostics ............................................................................................................. 5
Equipments & Instrumentations used in Fault Diagnostics ......................................................................... 6
Measuring instrumentations .................................................................................................................... 6
Vibration Meter PCE-VD 3..................................................................................................................... 6
Vibration Meter PCE-S 41: ........................................................................................................................ 7
Vibration Meter PCE-VMS 504 .................................................................................................................. 8
Fluke 810 Vibration Tester .................................................................................................................... 9
Faults ........................................................................................................................................................... 10
Gear wear fault ....................................................................................................................................... 10
Other Faults ............................................................................................................................................ 11
References .................................................................................................................................................. 11

Table of Figures
Figure 1- Condition Monitring....................................................................................................................... 3
Figure 2 - What to Measure for a fault ......................................................................................................... 4
Figure 3 Source of Vibration ......................................................................................................................... 4
Figure 4 - Spectrum of a Machine ................................................................................................................. 5
Figure 5 - Measurement References............................................................................................................. 5
Figure 6 - Trending in Vibration Signals ........................................................................................................ 6
Figure 7 - Vibration Meter ............................................................................................................................ 6
Figure 8 - Vibration Meter 2 ......................................................................................................................... 7
Figure 9 - Vibration Meter 3 ......................................................................................................................... 8
Figure 10 - Fluke 810 ..................................................................................................................................... 9
Figure 11 - Wear in Gears ........................................................................................................................... 10
Fault Diagnostics

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Introduction
Machine fault problems are broad sources of high maintenance cost and unwanted downtime across
the industries.
The prime objective of maintenance department is to keep machinery and plant equipments in good
operating condition that prevents failure and production loss.
Vibration signature analysis techniques for machine fault identification are the most popular among
other techniques.
Vibration monitoring is based on the principle that all the system produces vibration.
When a machine is operating properly, the vibration is small and constant, however, when faults
develop and some of the dynamic process in the machine changes, there will be changes in vibration
spectrum observed.
After the review of previous published work, it is concluded that gear fault, bearing fault, and coupling
fault are studied for research purpose to fault signature analysis.

Maintenance Engineering
There are many types of maintenance Engineering discipline but we will only care about the most 3
discipline that is relative in terms of Vibration usage in faults detection

Preventive Maintenance
Preventive maintenance (PM) consists of scheduled inspection and upkeep that is specifically intended
to prevent faults from occurring during subsequent operation. Inept PM, however, can also cause
problems.

Predictive Maintenance
Predictive maintenance is a preventive type of maintenance program that anticipates failures that can
be corrected before total failure. Predictive maintenance can also determine that a failure is about to
occur.

Unscheduled Maintenance
Unscheduled or nonscheduled maintenance must be done immediately when an emergency affects the
productivity of the plant. This is maintenance to fix what is broken or provide a work-around so that
the operation that was started can be finished

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Why Make Condition Monitoring

Condition Monitoring is one of the Predictive Maintenance techniques in fault detection of machine
elements

Figure 1- Condition Monitring

Fault Diagnostics
The main advantage of making vibration measurements on rotating machinery is the possibility to
detect faults, before they make the machine break down, and thereby reduce economic losses, such as
damaged equipment and production loss.
To this the constant percentage band width spectrum has shown to be the most efficient.

When a fault is detected, vibration analysis can be used to diagnose the fault.
Making diagnosis using vibration analysis requires skill and experience.
Additional measurements of FFT spectra and phase measurements is often required. In the following
some simple rules for the most common machine faults are drawn up giving the fault type and a
characteristic vibration measurement.
The spectrums in the examples are all made as drawings, in order to emphasize the typical feature of
each fault.

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There are mainly 5 techniques in measuring and detecting faults in any machinery systems which are the
following:

Figure 2 - What to Measure for a fault

But from where is the vibration is coming from in the first place the answer of this question will help us
to know more about the usage of vibration in fault diagnostics

So the next question that should

appear after knowing sources of
vibration is how can we allocate the
fault of machine element in a machine
that have many elements to operate
And that by using Spectrum graph
created by transducer signals that
have been filtered and processed
By vibration analyzer and finally
transformed from time wave form
spectrum using FFT
Figure 3 Source of Vibration

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Figure 4 - Spectrum of a Machine

Using Spectrum in Fault Diagnostics

Mainly there is two techniques are used for evaluating vibrations of machine elements in the spectrum
First : Making Reference for each measuring point and compare the results using ISO 10816 for nonrotating parts and ISO 10817 for rotating shafts.

Figure 5 - Measurement References

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Second Technique is Trending which we compare the results of single or Multi-Elements vibration
spectrum to specific dates assign by the predicative maintenance protocol of the organization or the
machine supplier.

Figure 6 - Trending in Vibration Signals

Equipments & Instrumentations used in Fault Diagnostics

Measuring instrumentations
Vibration Meter PCE-VD 3

Figure 7 - Vibration Meter

Usage :
it can be used for many different applications like, for instance, shipment control. Furthermore the
PCE-VD 3 vibration meter can be used for sports, medicine or for recording of movements 0f 1 to 3
axes.
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Features :
Measurement Range

18 g

Accuracy

0.5 g

Resolution

0.00625 g

Frequency Range

0 ... 60 Hz

Dimensions

95 x 28 x 21 mm

Power Supply

Interchangeable 3.6 V
lithium battery

How it measures :
Acceleration force is measured along the X, Y and Z axes. Since the PCE-VD 3 vibration meter is in
motion while it is recording data, alterations are recorded for the three axes. The PCE-VD 3 vibration
meter can be placed anywhere due to its robust and magnetic bracket
The internal sensor of the PCE-VD 3 vibration meter has a measurement range of 18g per axis. The
PCE-VD 3 vibration meter can be easily programmed through a software. All data can be sent to a PC
or portable computer via the USB port easily and quickly.

Vibration Meter PCE-S 41:

Figure 8 - Vibration Meter 2

Usage :
This Vibration Meter can be used for detecting noise in machine components, such as gears, valves,
vents and pumps This makes the Accelerometer a useful tool in inspecting noise and vibration, giving
the maintenance team the chance to locate the source of a problem before it becomes too costly.

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Features :
Frequency range

100 Hz to 10 kHz

Power

9V battery

Volume

Adjustable

Dimensions

206 x 50 x 32mm

Sensors (attachable)

1 x 290mm ; 1 x 70mm (long)

Sensor composition

Steel

Weight

240g, with battery

How it measures :
The enclosure of the accelerometer is made of ABS plastic which is comfortable to hold and operate.
The device uses a piezoelectric transducer which can detect very low resonant noises. The earpiece is
equipped with an adjustable headset that has a 2m cable.

Vibration Meter PCE-VMS 504

Figure 9 - Vibration Meter 3

Usage :
wireless vibration monitor with external vibration sensors/ to measure acceleration, speed, offset and
temperature
Features :
Communication type

wireless

Frequency band

GHz 2.4

Dimensions

250 x 210 x 100 mm

Weight

2400 g

Frequency range

5 Hz ... 10 kHz

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how it measures :
The wireless vibration monitor PCE-VMS 504 detects vibration within an acceleration range of up to 30
g and a frequency range between 5 and 10 KHz. The wireless vibration monitor therefore features
external vibration sensors, which measures vibrations at machines to transfer those wireless to a
receiving unit. Those sensors can be easily attached to a machine due to its magnetic base. There they
can not only measure vibrations at machines and transfer those to a computer but also recognize
temperatures between -20 and +120 C.
Fluke 810 Vibration Tester
Features and benefits
On-board identification and location of the most common mechanical faults (bearings,
misalignment, unbalance, looseness) focus maintenance efforts on root cause, reducing
unplanned downtime

Repair recommendations advise technicians on corrective action

On-board context sensitive help provides real-time tips and guidance to new users
2 GB expandable on-board memory provides enough space for your machinerys data
Self-test function ensures optimal performance and more time on the job
Tri-axial accelerometer reduces measurement time by 2/3 over single axis
accelerometers
Viewer PC Software expands data storage and tracking capacity

Use the Fluke 810 Vibration Tester to:

Troubleshoot problem equipment and understand the root cause of failure
Survey equipment before and after planned maintenance and confirm the repair
Commission new equipment and ensure proper installation
Provide quantifiable proof of equipment condition and drive investment in repair or
replacement
Manufacturer
Fluke USA

Figure 10 - Fluke 810

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Faults
Now we will try to give some practical examples on some of the most common faults in machine tools
and the way of detecting them also we will try to discuss some of the causes , treatment and prevention
techniques for some of the faults

Gear wear fault

Fault Name
Tooth wear

Fault Type
Gear Fault

Causes
1-Lack of lubrication
2-Over loading
3-Poor gear meshing
4-using different
meshing gear materials

Place
Any gear
meshing in
any machine.

Diagnosis
It could be
recognized
through
vibration
spectrum
analysis.
It will be appear
as a gradually
growing
frequency with
growing
amplitude with
lower side
bands
approximately
as shown in
figure

Treatment
After
wear in
gear there
is no
solution
except
changing
it.

Prevention
1-Monitor the
condition of the gear
mesh by schedule.
2-assureance of good
lubrication and
suitable working
conditions.

Figure 11 - Wear in Gears

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Other Faults

Fault Name

Causes

location

Diagnosis

Treatment

Prevention

Adding mass
Removing
mass
Shifting mass

Either the entire

rotor is balanced
or its individual
parts before the
final assembly and
then a final
balance is carried
out.

Unbalanced

The centrifugal force

that arise from:
In design (some parts
may be not perfectly
symmetrical)
Technological (nonhomogenous material)
manufacturing
(everything is produced
in some tolerances,
rotating parts exhibit
run out)
In mounting (namely
with mounted rotors)

In a rotor when
the mass center
axis is different
to its running
center axis.
At
1- Pump,
2- Fans,
3- Propellers
and
4- Turbo
machinery

From vibration
spectrum analysis:
Appear in high
vibration amplitude
in radial directions
at the rotational
component (1X).

Misalignment

Changes in clearances
result in worse machine
performance.
thermal growth
uneven applied loads
inappropriate
foundations

At rotating
systems: A
machine set
rotors one to
each other.
At
Gears,
Shafts,
etc.

Also from vibration

spectrum analysis:
Angular
Misalignment:
characterized by
large axial vibration,
which is out-ofphase

by a designer,
Enough combine
elements for
adjusting the
position of the
rotor axis towards
the axis of the
housing to the
construction and
Suitable choice of
rotor couplings,
including
measures to
establish their
parts one to each
other.

References
Machine Condition Monitoring by Dr Mohd Salman Leo - Institute of Noise & Vibration
University Technology Malaysia
Machine Fault Signature Analysis by Pratesh Jayaswal - International Journal of Rotating
Machinery Volume 2008 (2008), Article ID 583982
Maintenance Engineering Handbook Six Edition by Lindlet R.Hiffins Puplished by McGraw-Hill
Instrumentations Manufactures Websites
Fault Diagnostics

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