VISVESVARAYA TECHNOLOGICAL UNIVERSITY

BELGAUM

Seminar on

WEAR DEBRIS ANALYSIS

Under guidance of
Prof. Jagadish B.B BE M Tech

Presented by
Dnyaneshwar .B.Bairoji

A G M Rural College of Engineering and Technology,

Varur
Department of Mechanical Engineering
07/08/2021 1
 CONTENTS
 INTRODUCTION
 WEAR PROCESS MONITORING TECHNIQUES
 MAGNETIC PLUGS
 FERROGRAPHY
 ADVANTAGES
 APPLICATIONS
 CONCLUSION
 REFERENCE

07/08/2021 2
 INTRODUCTION
 Wear of sliding components result in reduced
mechanical efficiency.
 Lubrication is provided between the moving surface
to minimize the wear.
 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.
07/08/2021 3
 USED OIL CONTAMINATION – TIME
TRENDS

07/08/2021 4
• when the machinery is overheated, a sharp rise in
metallic concentration occurs from A to B .
• Once this phase is completed, the concentration
should remain steady, the oil should then be
changed. Some residual wear metal products
remain from the old oil and circulate in the original
oil following the oil change at c.

• Normal functioning the metallic concentration

would be expected to increase slowly as by C-D.
• If abnormal conditions arise, the concentration may
increase by D-E.
5
 WEAR PROCESS MONITORING
TECHNIQUES

07/08/2021 6
 MAGNETIC PLUGS

07/08/2021 7
It is an “on-line” control method, magnetic plugs are used in
oil-lubricated machines

 This method only detect ferrous material.

An unacceptable coating is visible. This indicates abnormal

wear.
Magnetic plugs are used in the modern aircraft engines where
particle sizes are in the order of 0.2-1 µm are found.

07/08/2021 8
 Ferrography
• Ferrography is a technique for analyzing contaminant particles
present in fluids. These fluids are commonly lubricating oils,
hydraulic fluids and greases used in machinery that is in danger
of mechanical wear.
• First developed by Vernon C. Westcott to analyse ferrous
particles in lubricating oils as a part of predictive maintenance.

• The method identifies, isolate and classify wear particles from

machine parts. A magnetic field is used to sort the wear
particles in the flowing oil.

• This technique was used successfully to monitor the condition

of military aircraft engines, gear boxes and transmissions.

07/08/2021 9
 Type of equipments used in wear particle
analysis
 Direct –Reading(DR) ferrography

 Analytical ferrograph system

 Ferrorgram scanner.

07/08/2021 10
 1. Direct – Reading (DR) Ferrography

07/08/2021 11
ANALYTICAL FERROGRAPHY

07/08/2021 12
 Ferrogram scanner

07/08/2021 13
ADVANTAGES OF FERROGRAPHY
Ferrographic analysis determines the number, size and
shape of wear particles.
Decrease of maintenance costs.
Effective maintenance scheduling.
Improved equipment reliability and safety.
Minimal machine power consumption over a period.
Reduction in unscheduled downtime due to wear of
rotary components such as gears and bearings.
Improves environmental cleanliness of the process, due
to optimized oil changes.
07/08/2021 14
 APPLICATIONS
It is used in situations where breakdowns are

catastrophic or expensive.

It is widely used in the military services.

It is used for many civil aviation companies.

07/08/2021 15
   CONCLUSION
The wear debris monitoring method access the
nature of the particles generated when
components wear.
They can indicate exact nature of the machine
problem.
Indicate the amount of debris present.
Indicate the size distribution of debris.
Indicate the physical form of debris.
Application of chemical analysis of debris.

07/08/2021 16
 REFERENCES
• Jian Ding. "Determining Fatigue Wear Using Wear Particle
Analysis Tools." Practicing Oil Analysis magazine, September 2003.
 
• Sabrin Gebarin and Jim Fitch. "Origin of Spherical Particles in
Lubricants." Practicing Oil Analysis magazine, March 2005.

• Ray Garvey. "Enhanced 5200 Minilab Offers Improved Oil

Analysis." Practicing Oil Analysis magazine, July 2005.

• System and Method for Filter Debris Analysis, International Patent

Application (PCT) Number PCT/SG2009/000465, date of filing
December 3, 2009.

07/08/2021 17
 Thank you

07/08/2021 18