Mr. Hossein Fazel Sarjoui Profile

Hossein Fazel Sarjoui

Structural Consultant

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Proceedings Article | 10 April 2014 Paper

Studying the effect of cracks on the ultrasonic wave propagation in a two dimensional gearbox finite element model

Didem Ozevin, Hossein Fazel, Justin Cox, William Hardman, Seth Kessler, Alan Timmons

Proceedings Volume 9063, 906303 (2014) https://doi.org/10.1117/12.2048519

KEYWORDS: Teeth, Wave propagation, Ultrasonics, Structural health monitoring, Finite element methods, Damage detection, Sensors, Wave plates, 3D modeling, Algorithm development

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Gearbox components of aerospace structures are typically made of brittle materials with high fracture toughness, but susceptible to fatigue failure due to continuous cyclic loading. Structural Health Monitoring (SHM) methods are used to monitor the crack growth in gearbox components. Damage detection methodologies developed in laboratory-scale experiments may not represent the actual gearbox structural configuration, and are usually not applicable to real application as the vibration and wave properties depend on the material, structural layers and thicknesses. Also, the sensor types and locations are key factors for frequency content of ultrasonic waves, which are essential features for pattern recognition algorithm development in noisy environments. Therefore, a deterministic damage detection methodology that considers all the variables influencing the waveform signature should be considered in the preliminary computation before any experimental test matrix. In order to achieve this goal, we developed two dimensional finite element models of a gearbox cross section from front view and shaft section. The cross section model consists of steel revolving teeth, a thin layer of oil, and retention plate. An ultrasonic wave up to 1 MHz frequency is generated, and waveform histories along the gearbox are recorded. The received waveforms under pristine and cracked conditions are compared in order to analyze the crack influence on the wave propagation in gearbox, which can be utilized by both active and passive SHM methods.

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