Application of micro-magnetic testing systems for non-destructive analysis of wear progress in case-hardened 16MnCr5 gear wheels
-
Jochen Tenkamp
Abstract
Micro-magnetic testing methods are qualified for non-destructive quantification of hardness, hardness depth and residual stresses. Among others they are applied for detection of grinding burn in gear wheels, but an application for wear condition monitoring has not yet been published. In this paper, results of initial research of determination of wear condition in gear wheels by application of micro-magnetic testing systems are presented. For comparison of different wear conditions, gears were loaded for increasing numbers of cycles in a test rig based on FVA information sheet 54/7 and DIN ISO 14635 part 1. Operating conditions were altered by usage of different lubricants. Afterwards, wear conditions were determined by conventional techniques, i. e., measuring change in profile and loss of material. Four measurement principles were evaluated for change in micro-magnetic properties determination, magnetic Barkhausen noise analysis, permeability and eddy-current measurements, as well as harmonic analysis of tangential field strength. A general suitability of micro-magnetic testing approach for characterization of wear condition of gear wheels could be demonstrated by comparison of micro-magnetic properties with common wear indicators. Micro-magnetic properties were not solely influenced by wear condition, as the selected oil, and hence the tribochemical conditions in contact also showed a significant effect on measured values. Therefore, further survey is required for direct correlation of micro-magnetic properties with (micro-)structural material changes.
Kurzfassung
Mikromagnetische Prüfverfahren wurden erfolgreich für die zerstörungsfreie Bestimmung von Härte, Einhärtetiefe und Eigenspannungen qualifiziert und werden derzeit u. a. zur Detektion von Schleifbrand in Zahnrädern eingesetzt. Eine Anwendung zur Überwachung des Verschleißzustands wurde allerdings noch nicht publiziert. In diesem Beitrag werden Ergebnisse erster Untersuchungen zur Bestimmung des Verschleißzustands mittels mikromagnetischer Prüfsysteme vorgestellt. Zum Vergleich unterschiedlicher Verschleißzustände wurden Zahnräder in einem Prüfstand basierend auf FVA Informationsblatt 54/7 und DIN ISO 14635 Teil 1 mit steigenden Lastspielzahlen beansprucht. Die Betriebsbedingungen wurden durch die Verwendung unterschiedlicher Schmierstoffe verändert. Im Anschluss erfolgte eine Quantifizierung der Verschleißzustände mit konventionellen Methoden, d. h. Messung der Profiländerung und des Materialverlusts. Veränderungen der mikromagnetischen Kenngrößen wurden mit zwei verschiedenen Prüfsystemen analysiert. Vier Messprinzipien wurden dabei evaluiert, die magnetische Barkhausenrauschen-Analyse, die Permeabilitäts- und Wirbelstrommessung sowie die Oberwellenanalyse der Stärke des Tangentialfelds. Durch Abgleich mikromagnetischer Kenngrößen mit bekannten Verschleißindikatoren, z. B. der Profiländerung, konnte eine generelle Anwendbarkeit des mikromagnetischen Prüfansatzes nachgewiesen werden. Die mikromagnetischen Eigenschaften wurden nicht ausschließlich durch den Verschleißzustand beeinflusst, da das gewählte Öl und folglich die tribochemischen Bedingungen im Wälzkontakt ebenfalls signifikante Auswirkungen auf die Messwertergebnisse zeigten. Weitere Untersuchungen zur direkten Korrelation der mikromagnetischen Eigenschaften mit den (mikro-) strukturellen Veränderungen des Werkstoffs schließen sich an.
References
1 User Manual FracDim Testing System, Fraunhofer IZFP, Saarbrücken, Dresden (2013), Doc. No.: HB 13002Search in Google Scholar
2 H.Kwun, G. L.Burkhardt: Non-destructive measurement of stress in ferromagnetic steels using harmonic analysis of induced voltage, NDT International20 (1987), No. 3, pp. 167–171 DOI: 10.1016/0963-8695(87)90325-2Search in Google Scholar
3 J.Schreiber, U.Cikalova, Y.Vertyagina: Use of the fractal nature of spatial and temporal response behavior for materials damage characterization, P. D.Portella (Ed.), T.Beck (Ed.), M.Okazaki (Ed.): Proc. of the 6th Intern. Conf. on Low Cycle Fatigue, DVM, Berlin, Germany (2008), pp. 655–660Search in Google Scholar
4 I.Mészáros: Magnetic characterisation of duplex stainless steel, Physica B372 (2006), No. 1, pp. 181–184 DOI: 10.1016/j.physb.2005.10.043Search in Google Scholar
5 S.Barteldes, F.Walther, W.Holweger: Residual stress progression and acoustic emission during lubrication-assisted white etching crack (WEC) formation, Proc. of STLE 2014 – Society of Tribologists and Lubrication Engineers Annual Meeting & Exhibition, Lake Buena Vista, USA (2014)Search in Google Scholar
6 G.Altpeter, M.Dobmann, M.Kröning, M.Rabung, S.Szielasko: Micro-magnetic evaluation of micro residual stresses of the IInd and IIIrd order, NDT & E International42 (2009), No. 4, pp. 283–290 DOI: 10.1016/j.ndteint.2008.11.007Search in Google Scholar
7 W.Holweger, F.Walther, J.Loos, M.Wolf, J.Schreiber, W.Dreher, N.Kern, S.Lutz: Non-destructive subsurface damage monitoring in bearings failure mode using fractal dimension analysis, Industrial Lubrication and Tribology64 (2012), No. 3, pp. 132–137 DOI: 10.1108/00368791211218650Search in Google Scholar
8 W.Holweger, M.Wolf, F.Walther, W.Trojahn, A.Mütze, J.Kunzmann, J.Schreiber, J.Mayer, M.Reichelt: Studies of the contribution of alternating electromagnetic fields towards material fatigue in 100Cr6, Industrial Lubrication and Tribology64 (2012), No. 5, pp. 247–252 DOI: 10.1108/00368791211249629Search in Google Scholar
9 G.Dobmann, I.Altpeter, B.Wolter, R.Kern: Industrial applications of 3MA-micromagnetic multiparameter microstructure and stress analysis, A.Tamburrino (Ed.), Y.Melikhov (Ed.), L.Udpa (Ed.): Electromagnetics Non-destructive Evaluation (XI), IOS Press, Amsterdam, the Netherlands (2008), pp. 18–25 DOI: 10.3233/978-1-58603-896-0-18Search in Google Scholar
10 D.O’Sullivan, M.Cotterell, D. A.Tanner, I.Mészáros: Characterisation of ferritic stainless steel by Barkhausen techniques, NDT & E International37 (2004), No. 6, pp. 489–496 DOI: 10.1016/j.ndteint.2004.01.001Search in Google Scholar
11 C.Lachmann, T.Nitschke-Pagel, H.Wohlfahrt: Characterisation of residual stress relaxation in fatigue loaded welded joints by X-ray diffraction and Barkhausen noise method, Materials Science Forum347 (2000), pp. 374–381 DOI: 10.4028/www.scientific.net/MSF.347-349.374Search in Google Scholar
12 FVA 54/7: Test Procedure for the Investigation of the Micro-Pitting Capacity of Gear Lubricants, Forschungsvereinigung Antriebstechnik e.V., Frankfurt, Germany (1993)Search in Google Scholar
13 DIN ISO 14635: FZG Test Procedures, Part 1, Beuth, Berlin, Germany (2006)Search in Google Scholar
© 2016, Carl Hanser Verlag, München
Articles in the same Issue
- Inhalt/Contents
- Contents
- Fachbeiträge/Technical Contributions
- Application of micro-magnetic testing systems for non-destructive analysis of wear progress in case-hardened 16MnCr5 gear wheels
- Weldability of duplex stainless steels with and without Cu/Ni interlayer using plasma arc welding
- TIG deposition of Ti on steel substrates using Cu as interlayer
- Examinations of casting cracks in a high alloy steel valve
- Analyzing the diffusion weldability of copper and porcelain
- Torsional behavior of a friction welded martensitic stainless steel
- Effects of different wire chemical compositions on the mechanical and microstructural characteristics of copper brazing joints
- Effect of Al addition on microstructure and properties of an Fe-B-Al alloy
- Inspection of domestic nuclear fuel rods using neutron radiography at the Tehran Research Reactor
- Strain measurement in concrete using embedded carbon roving-based sensors
- Wear behavior of multilayer coated carbide tools in finish dry hard turning
- Characteristics of austenitic stainless steel T-joints welded using the DMAG process with solid wire
- Application of the Taguchi method for surface roughness predictions in the turning process
- Experimental failure testing and repair of internal pressurized composite pipes using different fracture models
- Investigation of material removal rate (MRR) and wire wear ratio (WWR) for alloy Ti6Al4 V exposed to heat treatment processing in WEDM and optimization of parameters using Grey relational analysis
Articles in the same Issue
- Inhalt/Contents
- Contents
- Fachbeiträge/Technical Contributions
- Application of micro-magnetic testing systems for non-destructive analysis of wear progress in case-hardened 16MnCr5 gear wheels
- Weldability of duplex stainless steels with and without Cu/Ni interlayer using plasma arc welding
- TIG deposition of Ti on steel substrates using Cu as interlayer
- Examinations of casting cracks in a high alloy steel valve
- Analyzing the diffusion weldability of copper and porcelain
- Torsional behavior of a friction welded martensitic stainless steel
- Effects of different wire chemical compositions on the mechanical and microstructural characteristics of copper brazing joints
- Effect of Al addition on microstructure and properties of an Fe-B-Al alloy
- Inspection of domestic nuclear fuel rods using neutron radiography at the Tehran Research Reactor
- Strain measurement in concrete using embedded carbon roving-based sensors
- Wear behavior of multilayer coated carbide tools in finish dry hard turning
- Characteristics of austenitic stainless steel T-joints welded using the DMAG process with solid wire
- Application of the Taguchi method for surface roughness predictions in the turning process
- Experimental failure testing and repair of internal pressurized composite pipes using different fracture models
- Investigation of material removal rate (MRR) and wire wear ratio (WWR) for alloy Ti6Al4 V exposed to heat treatment processing in WEDM and optimization of parameters using Grey relational analysis