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American Journal of Science and Technology

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An Integrated Study of a Gearbox Failure

American Journal of Science and Technology
Vol.5 , No. 1, Publication Date: May 4, 2018, Page: 14-25

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Authors

[1]	Dalia Mohamed El-Gazzar, Mechanical & Electrical Research Institute, National Water Research Centre, Ministry of Water Resources & Irrigation, Delta Barrage, Egypt.

Abstract

Gearbox failures have a significant impact on the operational reliability. In this research, a significant, premature failure of a gearbox of an aeration unit was detected. This failure has occurred almost after 18 months of starting operation. The main objective of the present work is to investigate the main causes that leading to the gearbox failure. Also, how such a failure can be prevented in the future. The study is divided into three main parts. Firstly investigates gearbox internal components including gears, bearings, and shafts throughout the visual inspection and laboratory tests. Then investigate gearbox casing by performing stress analysis to determine stresses distribution and deformation. Finally, performing a dynamic analysis for measurements that were previously recorded before gearbox failure. The results showed that the failed aeration unit has suffered a severe unbalance problem. High vibration levels caused by the unbalancing effect led to excessive stresses. These stresses affected shafts, bearings, gears, casing, and promote fatigue failure. Vibration level decreased after applying balancing process for the fan. Recommendations pointed to the importance of balancing process of the fans before installation and performing a predictive maintenance program.

Keywords

Gearboxes, Vibration, Unbalance, Failure Analysis

Reference

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