Condition monitoring of rotating shafts is gaining importance in industry due to the need to increase machine reliability and decrease the possible loss of production due to machine breakdown. In this work, the use of vibration signals for the detection of a crack within a shaft was investigated. The research involved the measurement of vibration signals during laboratory tests on a long rotating shaft rig. The focus of the experimental work was on the effect of cracks on the dynamics and the initiation and growth of cracks in the shaft. Measurements were taken from the shaft system both with simulated cracks (notches) cut at 45° and 90° to the shaft axis and with real propagating cracks initiated by a pre-crack cut. All defects were located at the mid- point along the shaft. The vibration responses and stresses were measured for different depths of crack. The vibration responses of the three different defects were compared using PSDs of the data to identify the change in position and magnitude of the peaks in the spectrum under each defect. Experiments to study the effect of defect depth at different shaft rotation speeds were also carried out. Finally, a shaft with a breathing crack (continuously opening and closing as the shaft rotates) was also studied experimentally, with the crack growing under normal steady state operating conditions. After completing the experiment work, the shaft was broken and the type of fracture studied. The results for both simulated and actual crack growth showed that vibration frequencies decreased as a crack progressed, indicating the possibility of using the vibration signal for crack detection. A significant relationship was found between the stage of crack growth and the vibration results. A finite element (FE) model was constructed to explore the relationship between the natural frequencies and crack depth and position along the shaft and to explain and validate the results of the experimental work. The FE model showed similar trends to the experimental results and also allowed the effect of different crack positions to be explored. The PSD data was fed into an artificial neural network after a feature extraction procedure was applied to significantly reduce the quantity of data whilst at the same time retaining the salient information. Such an approach results in a considerably reduced training time for the network due to the reduced complexity. The proposed scheme was shown to successfully identify the different defect levels. This method greatly enhances the capacity of an automated diagnostic process by linking increased capability in signal analysis to the predictive capability of the artificial neural network.

Errata inserted / Bibliography: leaves 170-175 / iii, 175 leaves : ill ; 30 cm. / Title page, contents and abstract only. The complete thesis in print form is available from the University Library. / Thesis (Ph.D.)--University of Adelaide, 1987

An extensive research program was performed to investigate the load interaction effect of the combined action of small amplitude high R ratio cycles and large amplitude low R ratio underloads on the crack growth of large cracks. The study was driven by the needs of the damage tolerance approach in the helicopter structures, which requires robust knowledge on the crack growth behaviour of the advance high strength alloys under the characteristic helicopter spectra loading. The study was conducted on three metallic alloys, Ti-10V-2Fe-3Al, Al8090 T852 and Al7010 T76351 using compact tension specimens (w=70mm, t=17mm). The potential drop technique was used for the measurements of the crack length. The crack opening loads were determined from the applied load versus crack opening mouth displacement curve using a curve fitting technique and crack opening displacement gauge. The experimental results show that cracks can grow faster than the life predictions with no load interaction effects under spectra containing tensile underloads. The acceleration effects are different depending on the number of the small cycles, the Kmax, the R ratio of the small cycles, the underload cycle and the material. Significant closure observations on the underloads and on the small cycles of variable amplitude loading spectra were made. Based on the test finding and on the studies of other researchers, it is suggested that the acceleration effects are mainly due to the reduction of crack opening point of the tensile underloads comparing with the Constant Amplitude Loading (CAL) data. An extensive evaluation of the ability of FASTRAN model to predict the fatigue lives under the tested loading spectra was carried out. The evaluation focuses on the influence of the constraint factor a and the ∆Keff curve inputs on the predictions. The model produces very good and consistent predictions for the three alloys, when the inputs represent adequately the actual fatigue mechanism. The model predicts the measured acceleration effects by reducing the closure level of the underloads.

Dislocation channel-veins and persistent slip bands (PSBs) are characteristic dislocation configurations that are of interest to both industry and academia. However, existing mathematical models are not adequate to describe the mechanism of the transition between these two states. In this thesis, a series of models are proposed to give a quantitative description to such a transition. The full problem has been considered from two angles. Firstly, the general motion and instabilities of arbitrary curved dislocations have been studied both analytically and numerically. Then the law of motion and local expansions are used to track the shapes of screw segments moving through channels, which are believed to induce dislocation multiplication by cross-slip. The second approach has been to investigate the collective behavior of a large number of dislocations, both geometrically necessary and otherwise. The traditional method of multiple scales does not apply well to describe the pile-up of two arrays of dislocations of opposite signs on a pair of neighbouring glide planes in two dimensional space. Certain quantities have to be more accurately defined under the multiple-scale coordinates to capture the much more localised resultant stress caused by these dislocation pairs. Through detailed calculations, one-dimensional dipoles can be homogenised to obtain some insightful results both on a local scale where the dipole pattern is the key diagnostic and on a macroscopic scale on which density variations are of most interest. Equilibria of dislocation dipoles in a two-dimensional regular lattice have been also studied. Some natural transitions between different patterns can be found as a result of geometrical instabilities.

Cette thèse traite d’une approche pragmatique de l'endommagement par fatigue des structures sous un chargement cyclique. Un modèle anisotrope de dommage par fatigue a été développé. L'évolution de la dégradation des propriétés du matériau dépend d’un critère de fatigue (choisi) et de ses gradients. La dégradation du matériau anisotrope guidera la propagation des dommages. La propagation des dommages dépend principalement des crêtes de la «surface» du critère (gradients zéro). L'approche proposée décrit l'amorçage, la propagation des dommages et la rupture structurale sous un chargement multiaxial en fatigue. Pour chaque élément fini, des distributions anisotropes non homogènes des propriétés du matériau sont associées. Schématiquement, il apparaît comme un «surfer» matériel sur la «surface» du critère et les dommages suivent la crête de la «surface» du critère (niveau et gradient). Un critère d'approche globale, basé sur des invariants du tenseur des contraintes, est adopté. La réduction des propriétés des matériaux est affectée à un certain nombre de cycles et à un niveau global de contraintes, en utilisant une courbe de Wöhler expérimentale. Deux formes simplifiées du modèle sont proposées et les résultats sont comparés avec un exemple de référence expérimental (plaque cruciforme) et un cas industriel (pale d’une éolienne d’EDF). Une cartographie avec le critère de Dang Van est également calculée pour analyser les résultats numériques. / A new practical engineering methodology for the analysis of structures under cyclic loading is proposed in this work . A new anisotropic fatigue damage model is developed. The evolution of material properties degradation depends on a failure criterion and its gradient. The anisotropic material degradation will guide the damage propagation. The propagation of damage is mainly depending on the ridges of the criterion’s « surface » (zero gradients). The proposed approach can describe the initiation and propagation of the damage until the structural failure under fatigue loading. For each finite element, non-homogeneous anisotropic distributions of material properties are associated. Schematically, it seems like a material « surfing » on the criterion’s « surface » and damages follow the crest of the criterion’s « surface » (level and gradient). A global approach criterion, based on invariants of the stress tensor, is adopted. The reduction of material properties is assigned to a number of cycles and a global level of stresses, using an experimental Wöhler curve. Two simplified forms of the model are proposed and results are compared with a cruciform experimental reference example and an industrial case. A mapping with Dang Van criterion is also computed to analyze the numerical results.

This dissertation investigates the level of acid‐resistance of concrete degradation. Concrete specimens obtained from four mixtures (M1, M2, M3 and M4) were prepared with calcareous, siliceous and a blend of calcareous and silica sand; and then, tested in low (30 g/l) and highly (200 g/l) concentrated sulphuric acid solutions. To this end, an architecture of artificial neural networks (ANNs) was implemented to predict the performance of concrete specimens due to sulphuric acid solutions. Neural networks were composed with one hidden layer for one input and output layer. Nine input parameters were: cement composition, proportions of coarse and fine aggregates, water content, and compressive strength, weight loss of concrete, time impacting corrosion, acid concentration and sulphur concentration. Thickness expansion and concrete conductivity are used as output targets to evaluate the degree of deterioration. In this study, the learning through ANNs from training data sets have been proved to be better than measured data. Excellent results were found with a coefficient of determination (R2 ) of 0.9989, 0.9999, 0.9989 and 0.9998, respectively for the four mixtures M1, M2, M3 and M4 using siliceous aggregate. Also, the results show that two ANN models performed with both the thickness (expansion) and the electrical conductivity can successfully learn the prediction of concrete corrosion. In both low and highly concentrated sulphuric acid condition, the model thickness was more accurate in predicting concrete corrosion compared to the model conductivity. The lowest error in neural networks was provided by the mixture (M2) for the concrete using siliceous aggregate. For this purpose, the root mean squared error (RMSE) and the average absolute error (AAE) were of 0.0049 and 0.0048 % respectively. / College of Engineering, Science and Technology / M. Tech. (Chemical Engineering)

Dans cette thèse, j’ai conçu un nouveau test de rupture adapté à l’étude des matériaux fragiles sur une grande gamme de vitesse de fissure. Il a été mis en œuvre sur le PMMA, permettant de caractériser la transition entre un régime de rupture à grande vitesse v>vc=15 mms-1 avec des faciès optiquement plats et un autre régime pour v<vc avec une rugosité caractérisée par des motifs triangulaires. L’étude de la déformation du front dans le plan moyen de fissuration montre que le matériau est plus tenace à l’intérieur de ces triangles qu’à l’extérieur. Qui plus est, ces triangles sont décorés par de petits motifs en forme de toit d’usine, caractéristiques de l’instabilité de fragmentation sous mode I+III. Pour comprendre l’émergence de ces formes, nous revisitons tout d’abord les modèles de fragmentation en supposant que l’énergie de rupture dépend du cisaillement comme Gc(KIII/KI)=GcI[1+ (KIII/KI)2]. Le seuil de fragmentation (KIII/KI)thc ainsi prédit décroit significativement, réconciliant théorie et expérience. Le motifs triangulaires permettant de mesurer le paramètre exp à partir de la déformée du front et le degré de cisaillement (KIII/KI)exp par l’inclinaison des facettes qui est compatible avec la valeur de seuil prédite (KIII/KI)thc. A partir des valeurs exp et (KIII/KI)thc ainsi déterminées, nous prédisons que les facettes dérivent le long du front avec un angle compatible avec celui formé par les triangles. Cette compréhension fine de ces motifs nous permet donc de mettre en relation la transition rugueuse observée dans le PMMA avec l’instabilité de fragmentation et ouvre de nouvelles perspectives pour la compréhension de motifs similaires dans d’autres matériaux. / During this PhD thesis, a new fracture test geometry is designed for the accurate measurement of the fracture properties of brittle solids, subsequently applied to study failure in PMMA. At high crack speeds, their fracture surfaces are optically smooth. But below vc = 15 mms-1, a transition to rough surfaces occurs through the formation of puzzling triangular patterns. These patterns lead to significant toughening of the material that reflects through the pinned shape of the crack front as it crosses triangles. In addition, these triangles are found to be decorated by faceted features reminiscent of the crack front fragmentation instability in mode I+III. Assuming a shear-dependent fracture energy Gc(KIII/KI) = GcI[1+ (KIII/KI)2] we theoretically predict a fragmentation threshold (KIII/KI)thc that can be as low as a few percent while earlier models (that assumes = 0) predict a much larger value, inconsistent with various experimental observations. Applied to our experiments, this model allows us to measure exp from the deformation amplitude of the pinned front and the amount of applied shear (KIII/KI)exp from the facet inclination which is found to be compatible with the theoretically predicted threshold (KIII/KI)thc . Using the values (KIII/KI)exp and exp thus determined, one finally predict a drift of the facets from the propagation direction accounting for the triangle angle observed experimentally. To conclude, our study shows that the roughening transition in PMMA is a signature of front fragmentation under mode I+III. As a result, deciphering the triangular patterns at the transition led to significant improvements in the understanding of this instability.