ACKNOWLEDGEMENT

I would like to avail this opportunity to thank all of the people who have stood by
me in, encouraged me, inspired me and have contributed greatly in providing me in with
the joy of achievement and thrill of creative effort experienced by me all the way through
the accomplishment of the seminar work.
It’s my greatest privilege to express gratitude to my seminar guide Mr.Jagadish
B.B. Asst. Professor, Mechanical Engineering Department for his excellent guidance,
constant encouragement and help under his constant presence and valuable advice has led
to the completion of this seminar.
I would like to take this opportunity to express my gratitude for the support and
guidance of Project Co-ordinator Mr. Shivakant A. M. Asst. Professor, Mechanical
Engineering Department.
I wish to express my sincere thanks to Mr. Nandeesh M. Professor and HOD,
Mechanical Engineering Department for his valuable suggestions, help and support.
I sincerely thank Dr. Sunil Kumar D. Principal of AGMRCET, Varur for the
support he had provided in permitting me to undertake this Seminar Work.

DNYANESHWAR B. BAIROJI
(2AV14ME017)

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 ABSTRACT
Since the world’s resources of material and energy are getting progressively, by
necessity, there is growing involvement in studies of wear on a global basis. Wear of
sliding components result in reduced mechanical efficiency and an irretrievable loss of
material in the form of wear debris. Wear at the interface between moving particles is a
normal characteristic of machine operation. The kind and rate of wear depend on the
machine type. Lubrication is provided between the moving surface to minimize the wear
but during operations millions minute wear particles entering the lubricating oil. These
particles are in suspension in the oil, larger particles may be trapped by filter while others
generally too small to be removed, remain in suspension in the circulating oil.
Condition based monitoring has, in the past, been referred to as an art, when quite
clearly it is a science, and despites the cost of machine, surprisingly little attention has
been devoted to this science from the viewpoint of understanding and modelling failure
mechanisms and the study of probability to failure. Predictive maintenance technique has
now become common exercises as they maximize the machine availability time and
minimize the cost of maintenance, since the machine can be stopped just before as
impending problem in an otherwise healthy machine.
Fault detection using vibration analysis is difficult in very low speed and high load noisy
machines. In the case of slow speed bearing the vibration generated by damaged
components is very low, usually close to the floor noise and difficult to identify. In these
situations, Wear Debris Analysis has proven useful in providing supporting evidence on
the bearing or gear status. It also provides information on the wear mechanism, which is
involved.

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 CONTENTS
ACKNOWLEDGEMEN iii
T
iv
ABSTRACT
v
CONTENTS
vi
LIST OF FIGURES

CHAPTER 1 INTRODUCTION 1
1.1 Wear Particle Analysis Or
1
Ferrography
1.2 Problem Statement 2
CHAPTER 2 WORKING PRINCIPLE 3
3 WEAR DEBRIS ANALYSIS
CHAPTER 4
METHODS
3.1 Analytical Ferrography 4
3.2 Filter Patch Test 5
3.3 Lasernet Fines 5
3.4 Particle Quantifier Index 5
CHAPTER 4 WEAR PARTICLES 6
4.1 Types Of Wear Particles 6
4.1.
Normal Rubbing Wear 6
1
4.1.
Cutting Wear Particles 6
2
4.1.
Spherical Particles 7
3
4.1.
Severe Sliding 7
4
4.1.
Bearing Wear Particles 7
5
4.1.
Gear Wear 8
6
CHAPTER 5 ADVANTAGES 9
CHAPTER 6 APPLICATIOINS 10
CONCLUSION 14
REFERENCE 15

v
vi
 LIST OF FIGURES
Figure No. Name of the Figures Page No.

Figure 1.1 Types Of Ferrograms 1

Figure 6.1 Clinker Hammer Crusher 10

Figure 6.2 Stereoscopic Zoom Microscope 11

Large And Small Spherical Particles Found In A Bearing Grease
Figure 6.3 11
Sample
Figure 6.4 Defective Bearing Shows Signs Of Severe Wear 12

Figure 6.5 Analytical ferrography 13

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