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600-FKM (FYP1-PR-Rev.01)
A. PROPOSED PROJECT
1. PROJECT TITLE:
TEST BENCH UPGRADING AND SYSTEM INTERFACING FOR ULTRASONIC MEASUREMENT
2. STUDENT NAME:
MUHAMMAD ASHRAF BIN ZULKAFLI
3. STUDENT ID :
4.
COURSE
CODE : EM220
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A. PROJECT ABSTRACT
(Abstract of the proposed project in not more than 200 words):
(20 MARKS)
Lubricant is an important approach used to reduce friction between one or more contacting
surfaces. This is turn will lead to reduced amount of heat generated. The lubricant
properties are therefore very important due to its influence on the wear and efficiency of
the component. This study is conducted to determine the ultrasonic signals reflection
produced from different lubricant as well as its film thickness. The necessary apparatus are
used to measure the relevant parameters such as the reflection coefficient, R and the film
thickness, h are to be upgraded to enable it to have a live data feed instead of the previous
method of having to manually extract the data into the computer.
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B. PROJECT BACKGROUND
(Describe the background of your project)
(20 MARKS)
Lubrication refers to the approach used to reduce wear of one or more surfaces in
close proximity and moving relative to each other by separating the surfaces using a
substance called lubricant to transport the load between the opposing surfaces. From
practical experience, we know that by adding lubricant to a solid-solid contact will
significantly reduce friction and wear. Friction and wear has long been studied since the
functioning of many mechanical systems that depends on the appropriate friction and wear
value. The consequences of lubricant failure can be seen by increase in friction and wear
and the total failure of the mechanical system. Though the same can be said for over
lubrication as over lubrication of a moving surfaces leads to senseless energy expending
due to it trying to overcome churning losses. Due to this, the number of articles and papers
regarding the study of lubricant properties are gradually increasing.
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C. PROBLEM STATEMENT
(Please state clearly the problem of the proposed project)
(20 MARKS)
The previous set up of the measuring apparatus needs to have the user manually extract the
data from the oscilloscope, and then manually tabulated and processed in the Labview
software. This extra process is deemed as waste of time and effort as the user needs to
constantly work their way through manually tabulating and analyzing the data in the
Labview, thus the need for an upgrade of the current interface.
Another problem encountered for this interfacing project is the rate of transfer of the date
from the oscilloscope to the PC if live feed were to be used in the data acquisition process.
Thus a proper connection medium needs to be established to ensure that data transferred to
the PC is of a desired rate which is not too slow. Too slow of a transfer rate will result in
the loss of data, thus making the measuring process of the parameters to be not accurate.
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D.
(Please state the objectives and expected results of the proposed project)
(40 MARKS)
Objectives:
1. To develop a real time data processor system for ultrasonic measurement of film
thickness in a solid-liquid interface.
2. To measure viscosity of different lubricants through the use of ultrasonic reflection
method utilized in the developed system.
3. To compare the values obtained manually from the oscilloscope to the PC with the
data obtained through live feed to determine whether or not there is any difference
which might lead to error in measurements. Proper rectifying processes are done to
ensure that the accuracy of the measurements is at its best.
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Expected results:
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E. SCOPE OF WORK
(Describe the scope of the project)
(20 MARKS)
The scope of work for this project will focus primarily on the upgrading the interfacing
process of the ultrasound measurement technique for film thickness by using the Labview
software. The current set up of the measuring apparatus has no ability of obtaining live
data processing feed of the relevant measured ultrasonic parameters, where the date stored
in the oscilloscope has to be manually extracted to the computers Labview.
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F.
PROJECT METHODOLOGY
(Describe the procedures and methods to be used to achieve the project objectives)
(40 MARKS)
Literature Review
Identifying the all the equations used in obtaining the relevant parameters as well as the relevant software & hardware in use
Recognizing what connection is viable to connect the oscilloscope to the Labview software(PC). In which it is decided that the Ethernet cable shall b
Generate the necessary interface based on the previous apparatus set up.
Obtain a live feed connection between the computer and the Labview and generate the necessary data acquisition for data analysis
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(60 MARKS)
Non-destructive Testing
It is defined as wide group of analysis techniques used in science and industry to help
evaluate the properties of a material without impairing its usefulness.[1] Commonly used
techniques are:
1.
2.
3.
RT - Radiographic Testing
4.
UT-Ultrasonic Testing
5.
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Emergency
Stop
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Medical Imaging
Acoustic Sensors
Guided Waves
cavitation
Acoustic Microscopy
Nondestructive Evaluation
f (Hz)
Figure 1.2: Common frequency ranges for various ultrasonic processes. Source (David, J.
et al., 2012)
Ultrasonic
Ultrasonic is the application of ultrasound. It has many applications and covers a very
broad range of disciplines such as chemistry, physics, engineering, biology, food industry,
medicine, oceanography, seismology and so on. All of these applications are based on two
distinct features of ultrasonic waves which are:
1. Ultrasonic waves travel slowly, about 100,000 times slower than electromagnetic
waves. This makes way to display information in time, creating variable delay, and
so on.
2. Ultrasonic waves are able to penetrate opaque materials, whereas many other types
of radiations such as visible light cannot. Since ultrasonic wave source are
inexpensive, sensitive and reliable, this produces a highly desirable way to probe
and image the interior of the opaque objects. [2:1-2]
Wave Propagation
Wave propagation is defined as the direction of which the waves travel. With respect to the
direction of the oscillation relative to the direction of the propagation, we are able to
determine between longitudinal waves and transverse waves.
Ultrasonic waves can be classified into four groups which is:
1. Longitudinal (or Compression) waves
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Time Domain
Time domain is defined as the study of mathematical functions, physical signals, time
series of economics, environmental data, with respect to time. In the time domain, the
signal or functions value is noted for all real numbers for the case of continuous time, or at
various separate instants in the case of discrete time.
One of the most commonly used tools which operates in the time domain, is an
oscilloscope. It is used to visualize real world signals in the time domain. The Figure 1.5
below shows an example of data depicted with respect to time.
Figure 1.5
Frequency Domain
Like the time domain, it is the analysis of the above mentioned parameters although it is
analyzed with respect to frequency rather than time. Unlike the time-domain graph where it
shows how much a signal changes over time, the frequency-domain graph depicts how
much of the signal located within each frequency band over a range of frequencies.
Real world signals received in the time domain can be transformed to in terms of
frequency domain by utilizing mathematical operators called transform. The data depicted
in terms of frequency domain shall be used in this research for data processing to obtain
the necessary parameters. The Figure 1.6 below shows an example of data tabulated with
respect to time.
Figure 1.6
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The proportion of the incident signal reflected or the reflection coefficient, R can be
depicted by the equation below.
R=
z 1z 2
z1 + z 2
Where: z is the acoustic impedance of the media (given by the product of density and the
speed of sound).
The subscript is as reference to the two interfaces. ( z 1 &
z2 )
The transmission coefficient, T where the proportion of the incident signal transmitted can
be analyzed as the equation below.
T=1-R
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It is inferred that if the oil layer is sufficiently thick, or the ultrasonic wave bundle little
enough, then the reflections from the top and bottom bearing surfaces are discrete in time.
This expresses that if the speed of sound in the lubricant is known then the thickness of the
oil film can be dictated by measuring the time of flight (ToF) between the two reflections.
The amplitude of these reflected pulses can likewise be figured from equation 1 and 2, with
the assumption that the losses in the lubricants are small. The ToF method is normally used
for thickness gauging of metallic parts and for corrosion checking. The ToF method gets to
be less precise as the lubricant film gets to be thinner until for very thin layers, the
reflected pulses overlap and it gets difficult to determine the discrete reflection. The
thickest lubricant films are of or less than 50 m thick, consequently the ToF system is
rarely applicable.
It is a challenge to extract the thickness information from the reflections that are
overlapping in the time domain, for a practical lubricant film. Thus, comes the approach of
a quasi-static spring model which interprets and measures the amplitude of the reflected
signal provided that the lubricant-film thickness is so small that the frequency of the first
through-thickness resonance is above the measurable range. [4:959]
The response of a thin intermediate layer between two solid bodies to an ultrasonic wave
can be determined using a quasi-static spring model. The magnitude of the reflection
coefficient, |R| when the ultrasound is normally incident is given by:
|R| =
( z 1 z 2)2 + K 2 ( z 1z 2)2
( z 1 z 2 )2 + K 2 (z 1 + z 2)2
and the subscripts of 1 & 2 refer to the materials either side of the layer.
K is the stiffness of the interfacial layer, and represents the compression of the
layer with changing contact pressure.
In the context of such thin layers (thin with respect to the ultrasonic wavelength), the
reflection is dominated by the stiffness of the layer and it is assumed that mass and
damping have insignificant contribution to the coefficient of reflection.
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For analysis purposes, the layer can be a film of homogenous material(liquid or solid)
between two solid mediums, or a region of reduced stiffness, for example a rough surface
contact. This quasi-static spring model has been successful in the study of adhesive bonds,
cracks under compressive loading and rough surface contact phenomenon.
Oil films in engineering bearing component are typically very thin (and acoustically
dissimilar from the bearing materials) and through the spring model approach provides a
suitable method for interpreting their ultrasonic response. The stiffness of the oil film is a
function of its bulk modulus, B and film thickness, h according to:
K=
B
h
c 2
h
Where:
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Medium 0
T1
T0
T2
Medium 2
R0
R1
Medium 1
x=0
x=h
x
Figure 1.8: Schematic diagram of an ultrasonic wave travelling through a three-layer
system. Source (Reddyhoff, T. et al., 2005)
An incident acoustic displacement wave of unit amplitude propagating in medium 1 in the
direction of x can be represented with the equation ui = e i(t x /c )
i
At the interface between media 1 and 0, a fraction of the wave is transmitted into medium
0, while the other fraction is reflected back into medium 1. The part of the wave
transmitted through an interface is denoted as the transmission coefficient, T, while the part
reflected back is denoted as the reflection coefficient, R. The total displacements in media
1, 0, and 2 are therefore given by:
u1 (x) =
e
ix
c1
u0 (x) = T e
0
u2 (x) = T e
2
2
0
ix
c0
ix
c2
R1 e
+
ix
c1
R0 e
ix
c0
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e it
to x and applying the stress strain relationship gives the stress in each medium, .
E1
ix
( e c
c1
1 ( x ) = i
T0e
0( x ) =
2 ( x ) = i
Ei
Where
R 1 e
10
ix
c0
E0
c0
ix
c1
R0 e
ix
c0
11
ix
E2
( T e c )
c2
2
2
T0e
i z 0
0( x ) =
ix
c1
R 1 e
ix
c1
12
)
13
2 ( x ) = i z 2 ( T e
2
R0 e
ix
c2
ix
c0
14
With the assumption that interfaces 1-0 and 0-2 are perfectly bonded and have negligible
mass, then the boundary conditions of continuous stress and displacement are:
u1 (0) = u0 (0) ; u0 (h) = u2 (h)
1 (0) = 0 (0) ; 0 (h) = 2 (h)
15
16
ih
c0
ih
c0
( z 1 + z 0 ) ( z 0z 2 )e ( z 0z 1 )( z0 + z 2 )
ih
c0
17
ih
c0
( z 0z 1 ) ( z 2z 0 ) +e ( z1 + z 0 ) ( z 0z 2 )
The above equation is used as the exact analytical solution for the reflection coefficient
from a three layered system. This equation shall be simplified further by utilizing the
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Taylor series expansion for the special case where the intermediate layer is thin and of
lower acoustic impedance than the surrounding interface. Thus we obtain the below
equation:
R=
z 0 ( z 1z 2 )+ ih/c0 (z 1 z 2z 20)
z 0 ( z 1 + z 2 )+ ih/c0 (z 1 z 2+ z 20 )
18
If
z 0 is small compared to
z 1 and
( z1z 2 ) +ih/ z 0 c0 ( z 1 z 2)
R=
( z 1+ z 2 ) +ih/ z 0 c 0 (z 1 z 2 )
The acoustic impedance, z is then substituted as z =
( z1z 2 ) +ih/ 0 c 20 (z 1 z 2)
R=
2
( z 1+ z 2 ) +ih/ 0 c 0 ( z 1 z 2)
Combining equation (20) with equation (5) gives the reflection coefficient in terms of layer
stiffness K which depicts the reflection coefficient as a complex quantity containing
amplitude and phase information is obtained as below:
21
( z 1z 2 ) +i/ K ( z 1 z 2)
R=
( z 1 + z 2 )+ i/K (z1 z 2)
The reflection coefficient above, R has been derived in terms of displacement. If the
amplitude of the reflection coefficient is determined from equation (19) and equation (5) is
used to substitute oil film thickness, then the basic amplitude spring model, equation (3) is
obtained.
2 z 1 z 22 (
z 21 z22 (
)
K
2
) +(z 1 +z 2)2
K
( z 21z 22 )+ z 21 z 22( K )
2 2
z 1 z2 (
2
2
2
) +(z 1 + z 2)
K
600-FKM (FYP1-PR-Rev.01)
( )
The phase difference, between an incident and reflected wave, thus varies from 0 for a
thick film (K 0 ), to
/2
should be considered that if the second medium were acoustically less dense than the first (
z 2< z 1 ), then the phase difference for a vanishingly thin film would be . [6:4-6]
Figure 1.10: Schematic representation of the phase difference and amplitude reduction
between an incident and reflected wave at thick and thin oil films. Source (Dwycer-Joyce,
R.S et al., 2003)
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Bibliography
1.
http://www.engineeringtoolbox.com/ndt-non-destructive-testing-d_314.html
2.
http://www.ni.com/white-paper/6511/en/pdf
3.
David, J., Cheeke, N. Fundamentals and Applications of Ultrasonic Waves. New York, NY: CRC
Press, 2012, pp. 1-2
4.
Dwycer-Joyce, R.S., Drinkwater, B.W. and Donohoe, C.J (2003). The measurement of lubricantfilm thickness using ultrasound Proceedings of the Royal Society Series A: Mathematical Physical
and Engineering Sciences. [On-line]. 459(2032), pp.957-976. Available:
http://eprints.whiterose.ac.uk/169/1/dwyer-joycers1.pdf [Nov.10, 2014]
5.
https://www.ndeed.org/EducationResources/CommunityCollege/Ultrasonics/Physics/wavepropagation.htm
6.
Reddyhoff, T., Kasolang, S., Dwyer-Joyce, R.S. and Drinkwater, B.W. (2005). The phase shift of
an ultrasonic pulse at an oil layer and determination of film thickness Proceedings of the Institution
of Mechanical Engineers. [On-line]. 219(6), pp. 2-26. Available:
http://eprints.whiterose.ac.uk/9179/1/25_IMechE_pt_J_phase_paper_2005.pdf [Nov. 10, 2014]
H. PRELIMINARY OUTCOME
(Discuss the current status & expected outcomes of the project)
(80 MARKS)
Figure 2.1: The graph of amplitude against time data for SAE40 oil depicted in the
Labview
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Figure 2.2: The graph of amplitude against time for the reference signals.
Figure 2.3: The amplitude data of the SAE40 oil plotted against frequency after the Fast
Fourier Transformation
Figure 2.4: The amplitude data of the reference signal plotted against frequency after the
Fast Fourier Transformation thickness, h.
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Figure 2.5: The reflection coefficient, R plotted against multiple data points
The value of reflection coefficient, R obtained for the SAE oil is at 0.955139. All the above
figures are interfaces taken from the Labview for measurement process of the reflection
coefficient, R. This was done by manually extracting the data from the oscilloscope and
tabulating it in the Labview, thus our expected outcome at the end of this project is to have
the live feed measurements value up to par with the manually extracted data.
I.
PROJECT PLANNING
(List the main activities of the project. Indicate the length of time needed for each activity.)
2014
SEPTMBE
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oject Title
n Project
ound
nd Objectives
Review
Report
f Progress
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sentation
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DECEMBER
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