LAB 4

FAKULTI TEKNOLOGI KEJURUTERAAN

MEKANIKAL DAN PEMBUATAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BMMH 4593 HVAC APPLIED ACOUSTICS & VIBRATION

LAB SHEET 4

Vibration Monitoring – Shaft Crack

Learning Outcome LO2 Measure accurately the acoustics and vibration level of HVAC
(LO):
machinery and construct the control system.
Program Outcome: PO5 Ability to demonstrate an understanding of the impact of engineering
technology practices, taking into account the need for sustainable
development.
Synopsis: This lab activity will enrich students’ knowledge on analyze the vibration
spectrum from crack shaft.

Related Lecture’s Sound absorption

Topic:
Prepared by: TS. MUHAMMAD NUR BIN OTHMAN Date: 21 OCTOBER 2021

Approved by DR. MUHAMMAD ILMAN HAKIMI CHUA BIN Date

LM/SLM/HOD ABDULLAH

QMS : REVISION RECORDS

Revision Date Approved by

Description Prepared by :
No (DD/MM/YY) LM/SLM/HOD:
1.0 THEORY

A shaft crack at the protruding end of the shaft is to be simulated. The simulation will be
carried out using the short shaft with flange. The constant radial load is created using the
belt drive. The frequency spectra for the three experiments are to be compared.

The experiment will perform a shaft with a simulated crack. Cracks caused by material
fatigue are very dangerous for rotating machines as they often lead to the dreaded fatigue
fracture with fatal consequences. Therefore, early detection is vital step. A crack in the shaft
influences the shaft's vibration behaviour by changing its rigidity. These changes can be
identified by measuring the vibrations on the shaft and using appropriate analysis
software.

Safety
The experiment instructions, in particular the safety instructions, must be read thoroughly
prior to starting up the unit. Prior to starting the experiments, the participants are to be
briefed on the safety aspects and the correct handling of the unit. The signal words
DANGER, WARNING or CAUTION indicate the probability and potential severity of injury.
An additional symbol indicates the nature of the hazard (Figure 3.7).

2.0 EQUIPMENTS/ EXPERIMENT APPARATUS/ CONSUMABLE MATERIALS

This unit simulates the characteristic behaviour of a shaft with a crack using an
 asymmetrical flange connection (Figure 3.1 - Figure 3.3). Overall layout of the equipment
is shown in Figure 3.4. The flange connection is provided by six screws distributed around the
circumference. Tightening the flange connection with spacer sleeves gives a connection that
is either loose or secure depending on the installation direction of the spacer sleeves.
When rotated with a bending load, this flange connection results in intermittent separation
of the butt joint. This very closely resembles the behaviour of a crack in the shaft. To
create this behaviour, it is necessary to load the flange connection with a bending torque
(e.g. using the PT 500.14 belt drive or an imbalance from a weight).

Assembly of the flange connection for simulation of a crack

Align the flange with the shaft as shown in Fig. 3.4 (7 or 8) and pick up disc (4) using the
centering pin (3) and secure with the hexagon head screws (5).
 Fig 3.4 PT 500.11 - Crack Detection in Rotating Shaft Kit

It is important to understand; the discs cannot be centred using the screws alone.
Depending on the function, insert and tighten the spacer sleeves (6). The use of a spacer
sleeve for a loose connection can be seen in Fig. 3.5. In this type of connection, the
flange and pick up disc are held together by the screws with clearance. When using the
spacer sleeve for a secure connection, turn the spacer sleeve.
The use of a spacer sleeve for a secure connection can be seen in Fig. 3.6. In this type of
connection, the flange and pick up disc are held together by the screws force with no
clearance. Insert the shaft clamping set (2) in the pickup disc (4). Fit the "shaft with crack"
in the experimental setup on one end of the short shaft using the shaft clamping set.
 NOTICE
At least two screws in the flange connection must be securely tightened to give a
secure connection with no clearance. For safety and to prevent imbalances, all
screws must always be fitted.
At least two of the six hexagon head screws distributed around the circumference
must be securely tightened with no clearance with spacer sleeves.

3.0 PROCEDURES/ METHODOLOGY

Fig 4.1 Schematic diagram above testing apparatus

1. The simulation of "crack in shaft" with protruding shaft end experiment can be performed
as set up illustrate in Fig 4.1.
 2. Prepare the "shaft without crack" for the experimental process, i.e. fit all six screws with
spacer sleeves as a secure connection.
3. The flange should be fitted as described below.

Simulation of shaft without crack

Six hexagon head screws with spacer

sleeves installed as a secure connection
(Fig.4.2).
Shaft with crack

Four hexagon head screws with spacer

sleeves as a loose connection (Fig. 3.5).
Two hexagon head screws with spacer
sleeves as a secure connection (Fig.3.6)
4. Secure the small belt pulley (3) to the end of the short shaft with flange using the
clamping set.

Assemble the belt drive with the bearing

block and belt tensioner from the PT
500.14 (belt drive), align and slightly
tension the belt.
The correct direction of rotation must be
ensured. The belt tensioner must be
fitted on the unloaded side of the belt.
The belt tension (Fig. 4.3) can be
adjusted using the belt tensioner. For
each belt drive, the adjusting screw
moves a tension roller into the loose
side of the belt from below until the belt
is slightly tensioned.
 iii. Adjust the belt tension for the
shaft with crack. The belt tension
should be increased until the feeler
fits 0.4 mm into the gap between
the flange on the side opposite the
supporting screws. A measurement
should also be carried out on the
side opposite the belt drive (on the
side where tensile stress is acting
on the shaft).

iv. Alternatively, the tensile stress of the

belt can be measured using the
belt pretension measuring unit
(Fig. 4.5).

5. The switching behavior of the reference sensor. The second LED directly on the reference
sensor may only trip once when scanning the reflective mark is checked.

6. In the software, open the "Sensor" window.

i. Select the sensor and check the settings in
ii. the "Calibration" menu.
iii. Sensor: Acceleration
iv. Scale: 100 mV/g
v. Offset: 0.0
vi. Factor: 1.0
vii. Gain on measuring amplifier: 1Ox

7. In the software, open the "Frequency Spectrum" window and check the following settings.
 i. ChannelA:Channel 1
ii. Channel B: Reference
iii. Scan Rate: 8 k/s
iv. Scan Time: 4 Seconds
v. Of Means: 1
vi. Mode: Velocity
vii. Window Function: Uniform
viii. Log Or Linear: Linear
ix. Unit Of Magnitude: rms

8. Recording the frequency spectrum

i. All parts are fitted securely is checked.
ii. The protective hood is closed.
iii. The control unit for the motor is switched on.
iv. The rotation (determined by the belt drive - the belt tensioner should act on
the loose side) is set to the direction.
v. The speed to zero is set.
vi. The motor is switched on.
vii. The speed (1200 -1800 rpm) is set.
viii. The frequency spectrum is plotted.
ix. The speed to zero is set.
x. The motor is switched off.
9. The "shaft with small crack" for the experimental process, i.e. fit five adjacent screws
with spacer sleeves as a secure connection and the other three as a loose connection is
prepared. Step 6 - 7 above is repeated.

10. The "shaft with crack" for the experimental process, i.e. fit two adjacent screws with
spacer sleeves as a secure connection and the other four as a loose connection is
prepared. Step 6 - 7 above is repeated.

Note: To show the difference in the comparison, the "shaft without crack" is recorded first

4.0 RESULTS
NO CRACK 1200 RPM

NO CRACK 1800 RPM

SMALL CRACK 1200 RPM

SMALL CRACK 1800 RPM

MAXIMUM CRACK 1200 RPM

MAXIMUM CRACK 1800 RPM

5.0 DISCUSSION
The factor that causes vibration on the shaft is the imbalance shaft. Imbalanced. Imbalance can be caused
by manufacturing defects or during maintenance work. As the shaft speed rotation increases the vibration
becomes greater. Next, shaft misalignment can cause vibration due to improper installation or improper
maintenance time schedule. Next, wear components such as a ball or roller bearing. The bearing can cause
a vibration when it becomes pitted and the drive belt also can produce vibration when it breaks down. Last
but not least, a loose screw/nut also can contribute to the vibration that can lead to damage to the shaft or
bearing.

From this experiment, we make an observation on three different conditions with 2 different speeds of
rotation. The maximum crack shows a high Amplitude value of 2.1872. We can assure that looseness is a big
factor in this experiment. If the shaft has no crack, then the reading frequency taken is high compared shaft
with a small crack and maximum crack.

6.0 CONCLUSION
 ASSESSMENT CRITERIA:

Your response to each task will be graded separately based on the checklist attached. To
obtain maximum marks, ensure that your response addresses each of the tasks in the
question accordingly.
Assessment checklist for Lab Activity

Assessment tasks Mark LO PO C/P/A level

allocation
P3 –
Procedure: Ability to understand and 10 LO2 PO5
Guided
perform the procedure
response

Outcome (Results):
30 LO2 PO5 P4 – Mechanism
1) Ability to display data in correct figure
and/or table format.

Outcome (Discussion) P5 – Complex

30 LO2 PO5
Ability to interpret system data and trend Overt Response
correctly.
1) Ability to provide observation and
comments related to the interpretation.

Outcome (Conclusion)
10 LO2 PO5 P5 – Complex
Overt Response
Outcome (Question)
20 LO2 PO5 P5 – Complex
Overt Response
TOTAL 100

SPECIFIC INSTRUCTION

1. Answer in ENGLISH.
2. Must include list of references.
3. Submit your report ONCE only in a SINGLE file.
4. Submit your report ONLINE.
5. This lab report/activity accounts for 5% of the total marks for the course.
 LAB 4
FAKULTI TEKNOLOGI KEJURUTERAAN
MEKANIKAL DAN PEMBUATAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BMMH 4593 HVAC APPLIED ACOUSTICS & VIBRATION

LAB 4

Vibration Monitoring – Shaft Crack

INSTRUCTOR’S NAME TS FAEZ BIN ZAINOL

STUDENT’S NAME MATRIX NO:

S1. HARRIS ANAK SMAIL B092010201
S2. ADIE ZULFIKRI BIN MAZLAN B092010215
S3. HAZRIQ HAKIM B JULAILI B092010428

ASSESSEMENT RUBRICS

MARK GIVEN MARKS

ASSESSMENT TASK/ITEMS
ALLOCATION

1. Procedure: Ability to understand and perform the procedure 10

2. Outcome (Results): 30
Ability to display data in correct figure and/or table format.
3. Outcome (Discussion): 30
Ability to interpret system data and trend correctly.
Ability to provide observation and comments related to the interpretation. .
4. Conclusion 10

5. Question 20
TOTAL MARKS 100

Approved By:

………………………………………………..…..
(Instructor’s Signature & Stamp)

Date: …………………………………………….........
 Very Weak Weak Modest Good Excellent
Item Description
0 1 2 3 4
Ability to Unable to
All procedures
understand identify Some written All procedures
Major written are good written
the procedure procedure and procedures are are well written
procedure stated but could
and write the totally wrong missing but completely
Procedure incorrect still be improved
procedure acceptable without missing
completely

Data, figures, All data,

Most data, All data, figures,
graphs, tables, figures,
figures, graphs, graphs, tables,
diagrams, contain graphs, tables,
tables, diagram diagram, are
Show results errors or are poorly diagrams are
No record of are recorded, correctly drawn,
(Simulation constructed, have correctly
results at all in some labeled and labeled but
and/or missing titles, drawn, are
any form. still missing some have
Hardware) captions, labeled numbered, are
some important minor problems
or numbers, units labeled and
or required or could still be
missing or contain
features improved
incorrect, etc. titles/captions.
All important
trends and
Outcome No Some of the
Incomplete or Almost all of the data
interpretation of results have
incorrect results have comparisons
trends and been correctly
interpretation of been correctly have been
comparison of interpreted and
trends and interpreted and interpreted
Discussion data, discussed;
comparison of discussed. correctly and
observation understanding of
data, observation Observation and discussed.
and conclusion results is still
and conclusion comments are Understanding
indicating a evident,
indicating a lack of good. Requires of results is
lack of observation and
understanding of only minor conveyed
understanding comments are
results. improvements. through
of results. acceptable.
observation
and comments.
Conclusion No Conclusion Incomplete Good conclusion
Conclusion

Question Not Answered Incorrect or Almost all All question was

incomplete answer question answered
was given. answered perfectly.
correctly.