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Application of micro-magnetic testing systems for non-destructive analysis of wear progress in case-hardened 16MnCr5 gear wheels

  • Jochen Tenkamp , Matthias Haack , Frank Walther , Max Weibring and Peter Tenberge
Published/Copyright: August 30, 2016
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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.


*Correspondence Address, Dipl.-Ing. Matthias Haack, Institute for Design and Materials Testing (IKW), Department of Materials Test Engineering (WPT), TU Dortmund University, Baroper Str. 303, D 44227 Dortmund, Germany, E-mail:

M.Sc. Jochen Tenkamp, born in 1988, studied Mechanical Engineering with specialization in Materials Technology and Testing at TU Dortmund University, Germany. After his master thesis, he has been working as a scientific assistant in the Department of Materials Test Engineering (WPT) of TU Dortmund University. His research focus is on fatigue and fracture of metals.

Dipl.-Ing. Matthias Haack, born in 1984, studied Mechanical Engineering with specialization in Materials Technology and Quality Control at TU Dortmund University, Germany. After his diploma thesis, he has been working as a scientific assistant in the Department of Materials Test Engineering (WPT) at TU Dortmund University. His research focus is on fatigue and fracture of composites and hybrid materials.

Prof. Dr.-Ing. Frank Walther, born in 1970, studied Mechanical Engineering with a major in Materials Science and Engineering at TU Kaiserslautern University, Germany. There he finished his PhD on the fatigue assessment of highly loaded railway wheel steels at the Chair of Materials Science and Engineering (WKK) in 2002. Until 2008, he headed the research group Fatigue Behaviour at WKK and finished his postdoctoral qualification (habilitation) in Materials Science and Engineering in 2007. Then, he joined Schaeffler in Herzogenaurach, Germany, and was responsible for Public Private Partnership within Corporate Development. Since 2010, he has been Professor for Materials Test Engineering (WPT) at TU Dortmund University, Germany. His research portfolio includes the determination of structure-property relationships of metal- and polymer-based material systems, taking into account the influence of manufacturing and joining processes as well as service-relevant loading and environmental conditions. He focuses on measurement and testing approaches for fatigue assessment from LCF to the VHCF range, physically-based deformation and damage development modeling and (remaining) fatigue life calculation.

M.Sc. Max Weibring, born in 1987, studied Mechanical Engineering with specialization in Engineering Design and Automation at Ruhr University Bochum (RUB), Germany. Since 2014, he has been working as a scientific assistant at the Chair for Industrial and Automotive Drivetrains at Ruhr University Bochum. His research focus is on fatigue of metals, in particular on the simulation of pitting damages on gear tooth flanks.

Prof. Dr.-Ing. Peter Tenberge, born in 1956, studied Mechanical Engineering, majoring in Engineering Design at Ruhr University Bochum (RUB), Germany. Subsequently, he worked as a scientific assistant at the Chair of Machine Elements and Gears at RUB and finished his PhD on the topic of transmissions. From 1986 to 1994, he worked for Zahnradfabrik Friedrichshafen and Schaeffler, Germany, at the end as manager for automotive components. From 1994 to 2012, he was Professor for Machine Elements at the Technical University in Chemnitz, Germany. Since 2012, he is Professor for Industrial and Automotive Drivetrains at RUB in Bochum.


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Published Online: 2016-08-30
Published in Print: 2016-09-07

© 2016, Carl Hanser Verlag, München

Articles in the same Issue

  1. Inhalt/Contents
  2. Contents
  3. Fachbeiträge/Technical Contributions
  4. Application of micro-magnetic testing systems for non-destructive analysis of wear progress in case-hardened 16MnCr5 gear wheels
  5. Weldability of duplex stainless steels with and without Cu/Ni interlayer using plasma arc welding
  6. TIG deposition of Ti on steel substrates using Cu as interlayer
  7. Examinations of casting cracks in a high alloy steel valve
  8. Analyzing the diffusion weldability of copper and porcelain
  9. Torsional behavior of a friction welded martensitic stainless steel
  10. Effects of different wire chemical compositions on the mechanical and microstructural characteristics of copper brazing joints
  11. Effect of Al addition on microstructure and properties of an Fe-B-Al alloy
  12. Inspection of domestic nuclear fuel rods using neutron radiography at the Tehran Research Reactor
  13. Strain measurement in concrete using embedded carbon roving-based sensors
  14. Wear behavior of multilayer coated carbide tools in finish dry hard turning
  15. Characteristics of austenitic stainless steel T-joints welded using the DMAG process with solid wire
  16. Application of the Taguchi method for surface roughness predictions in the turning process
  17. Experimental failure testing and repair of internal pressurized composite pipes using different fracture models
  18. 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
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