A novel baseline-free approach for acousto-ultrasonic crack monitoring of rotating axles

Axles are widely used mechanical components in rotating machines. In many applications, axles are exposed to varying environmental and operational conditions, including for example, temperature, load and rotational speed. To apply acousto-ultrasonics–based structural health monitoring for axles, it is in some cases not economically feasible to collect data and to construct a baseline model for each combination of all possible environmental and operational conditions. In consideration of such a practical limit, a novel baseline-free method, called Dynamic Reference Method, is proposed in this article for the detection of transverse cracks in axles. Piezoelectric wafer active sensors are applied for exciting and sensing ultrasonic waves. In case a transverse crack is present in an axle, it is noticed that the crack will sequentially open and close within one revolution of the axle when it is mechanically loaded in the radial direction. Such an opening and closing phenomenon of the transverse crack will influence the propagation of the ultrasonic waves. During the short time of data acquisition, the environmental and operational conditions remain nearly constant and the changes in the propagation of the ultrasonic waves may indicate the appearance of a transverse crack on the axle, and a baseline model for the environmental and operational conditions is not needed. To validate the proposed baseline-free method, an axle is put on a rotating bending test rig to first initiate a fatigue crack on the surface of the axle and second to observe its growth. During the test, the ultrasonic waves are measured by piezoelectric wafer active sensor in situ and are analysed online using the proposed baseline-free method. According to the test results, not only can the crack be effectively detected, but also the progressive changes of the crack size can be differentiated. Such results demonstrate the potential of the proposed baseline-free method in condition-based maintenance and predictive maintenance for critical axle components.

Influence of a delamination on Lamb wave excitation by a nearby piezoelectric transducer

This article presents the results of theoretical and experimental investigations of characteristic changes of Lamb wave excitation and scattering by a strip-like horizontal delamination in a layered elastic waveguide for Lamb waves induced by a piezoelectric wafer active sensor. The boundary integral equation method is used to describe wave propagation in an infinite layered waveguide with a delamination, while the frequency domain spectral element method is employed to model the dynamic behaviour of the piezoelectric wafer active sensor, which allows to simulate debonding between the piezoelectric wafer active sensor and the waveguide. Experimental investigations of the dynamic interaction of the piezoelectric wafer active sensor with a layered plate containing a horizontal delamination is conducted for several damage scenarios, showing a good agreement with the results obtained using the developed mathematical model. The obtained mathematical model is employed to analyse alteration of the piezo-induced Lamb waves including modes’ decomposition due to delamination. The conversion and/or conservation of the Lamb waves on account of a delamination is investigated. The electro-mechanical impedance of the piezoelectric transducer and the stress intensity factors of a delamination are analysed in dependence on the delamination location.