Vibration based diagnostics on rolling contact fatigue test bench

Abstract The paper presents the first results of a study on vibrations associated with a rolling contact fatigue test bench and how this mechanical behavior may be correlated to the fatigue damage of the specimens. In particular, the aim of this study was to evaluate the possibility to detect and quantify, thanks to vibration analysis, the damage on two discs subjected to rolling contact fatigue. The first part of this work regards a description of the bench with a focus on the results acquired by its static and modal fem analyses. Then, some pure rolling and sliding condition tests were carried out and a procedure to monitor both the specimens damage state and to record accelerometric data was implemented by placing a set of piezoaccelerometers on the machine and developing a virtual instrument for automatic data handling and analysis. Tests were also periodically stoppedand the rolling contact surface profile was acquired by means of a linear video camera in order to evaluate its progressive damage. Data acquired were analyzed, considering also the results from the first part of work, both using a standard approach, such as a spectral analysis (FFT, PSD and waterfall), and by implementing custom digital weighting filters for a windowed RMS in order to estimate, realtime during the measurement, a good estimator for the specimen damage state development.