Health monitoring of rotating machinery, particularly gearboxes, is crucial for ensuring operational efficiency and preventing unexpected failures. Gearboxes are among the most critical components in rotating machinery, with gears playing an essential role in transmitting torque and maintaining appropriate speeds. Due to the importance of fault diagnosis and predicting the remaining useful life (RUL) of gearboxes, numerous studies have recently been conducted in this area. One widely used method for predicting the RUL of equipment is accelerated life testing. To achieve this, a test bench was designed using CATIA software to estimate the RUL of spur gears, which are key components of gearboxes. Subsequently, dynamic and vibrational analyses were conducted using ADAMS software. These analyses included investigating the impact of vibration interference caused by the operation of the crank and spring mechanism—a load applicator on the gear teeth. Simulation results were compared with experimental data, confirming the model's accuracy. Additionally, vibrations from the crank and spring mechanism did not affect data related to gear faults. Experimental data collected from the system showed that the engagement frequency range of the gear increased from 44.5 dB to 66.87 dB, and the presence of sidebands around this frequency indicated wear-related faults. The findings of this research suggest that the collected data can be effectively used to estimate the remaining useful life of gearboxes.
[1] X. Liang, M. J. Zuo, and Z. Feng, "Dynamic modeling of gearbox faults: A review," Syst. Signal Process., vol. 98, pp. 852–876, 2018. doi: 10.1016/j.ymssp.2017.05.024.
[2] W. Caesarendra, A. Widodo, and B. S. Yang, "Combination of probability approach and support vector machine towards machine health prognostics," Probabilistic Eng. Mech., vol. 26, no. 2, pp. 165–173, 2011. doi: 1016/j.probengmech.2010.09.008.
[3] G. Dalpiaz, A. Rivola, and R. Rubini, "Effectiveness and sensitivity of vibration processing techniques for local fault detection in gears," Syst. Signal Process., vol. 14, no. 3, pp. 387–412, 2000. doi: 10.1006/mssp.1999.1294.
[4] K. Feng, W. A. Smith, R. B. Randall, H. Wu, and Z. Peng, "Vibration-based monitoring and prediction of surface profile change and pitting density in a spur gear wear process," Syst. Signal Process., vol. 165, p. 108319, 2022. doi: 10.1016/j.ymssp.2021.108319.
[5] O. D. Mohammed and M. Rantatalo, "Gear fault models and dynamics-based modelling for gear fault detection–A review," Fail. Anal., vol. 117, p. 104798, 2020. doi: 10.1016/j.engfailanal.2020.104798.
[6] J. Xia, R. Huang, Y. Liao, J. Li, Z. Chen, and W. Li, "Digital twin-assisted gearbox dynamic model updating toward fault diagnosis," Mech. Eng., vol. 18, no. 2, p. 32, 2023. doi: 10.1007/S11465-023-0748-0.
[7] Q. Chen, Y. Ma, S. Huang, and H. Zhai, "Research on gears’ dynamic performance influenced by gear backlash based on fractal theory," Surf. Sci., vol. 313, pp. 325–332, 2014. doi: 10.1016/J.APSUSC.2014.05.210.
[8] A. Kahraman and R. Singh, "Non-linear dynamics of a spur gear pair," Sound Vib., vol. 142, no. 1, pp. 49–75, 1990. doi: 10.1016/0022-460X(90)90582-K.
[9] S. Ebrahimi and P. Eberhard, "Rigid-elastic modeling of meshing gear wheels in multibody systems," Multibody Syst. Dyn., vol. 16, pp. 55–71, 2006. doi: 1007/S11044-006-9021-7.
[10] Y. Wang, H. M. E. Cheung, and W. J. Zhang, "Finite element modelling of geared multi‐body system," Numer. Methods Eng., vol. 18, no. 11, pp. 765–778, 2002. doi: 10.1002/CNM.526.
[11] G. Litak and M. I. Friswell, "Dynamics of a gear system with faults in meshing stiffness," Nonlinear Dyn., vol. 41, pp. 415–421, 2005. doi: 1007/S11071-005-1398-Y.
[12] G. A. Ambaye and H. G. Lemu, "Dynamic analysis of spur gear with backlash using ADAMS," Today: Proc., vol. 38, pp. 2959–2967, 2021. doi: 10.1016/j.matpr.2020.09.309.
[13] R. K. Y. Chang, C. K. Loo, and M. V. C. Rao, "Enhanced probabilistic neural network with data imputation capabilities for machine-fault classification," Neural Comput. Appl., vol. 18, pp. 791–800, 2009. doi: 1007/s00521-008-0215-1.
Zamani,M , Aboonajmi,M , Hassan beygi,S R and Moosavian,S A . (2025). Design, Evaluation and Construction of a Test Rig For Predicting the Remaining Usefull Life of a Gearbox with a Spur Gear. Science and Technology in Mechanical Engineering, 3(2), 33-46. doi: 10.22034/stme.2025.487070.1087
MLA
Zamani,M , , Aboonajmi,M , , Hassan beygi,S R , and Moosavian,S A . "Design, Evaluation and Construction of a Test Rig For Predicting the Remaining Usefull Life of a Gearbox with a Spur Gear", Science and Technology in Mechanical Engineering, 3, 2, 2025, 33-46. doi: 10.22034/stme.2025.487070.1087
HARVARD
Zamani M, Aboonajmi M, Hassan beygi S R, Moosavian S A. (2025). 'Design, Evaluation and Construction of a Test Rig For Predicting the Remaining Usefull Life of a Gearbox with a Spur Gear', Science and Technology in Mechanical Engineering, 3(2), pp. 33-46. doi: 10.22034/stme.2025.487070.1087
CHICAGO
M Zamani, M Aboonajmi, S R Hassan beygi and S A Moosavian, "Design, Evaluation and Construction of a Test Rig For Predicting the Remaining Usefull Life of a Gearbox with a Spur Gear," Science and Technology in Mechanical Engineering, 3 2 (2025): 33-46, doi: 10.22034/stme.2025.487070.1087
VANCOUVER
Zamani M, Aboonajmi M, Hassan beygi S R, Moosavian S A. Design, Evaluation and Construction of a Test Rig For Predicting the Remaining Usefull Life of a Gearbox with a Spur Gear. STME. 2025;3(2):33-46 (In Persian). doi: 10.22034/stme.2025.487070.1087
Science and Technology in Mechanical Engineering