Experimental investigation and comparative analysis of various condition-based monitoring techniques for wear recognition in gear pump Nihal Dhote, Mohan Khond Proceedings of the Institution of Mechanical Engineers Part J Journal of Engineering Tribology, 2025 The purpose of the presented work is to recognize wear in different parts of the gear pump and to determine the wear particle contamination and particle types in oil. Oil samples were collected intermittently from the gear pump test rig to find the wear severity index and particle contamination. The percentage of large particles increased to 80.49% with wear severity index at the end of the test due to contamination. Hence ferrogram slides were prepared and observed under a bichromatic microscope to identify the types of wear particles. These ferrogram slides of oil samples show normal rubbing, severe sliding and cutting wear particles with some red oxide due to moisture content in the oil. Later on, to find the extent of damage to the gear pump parts, surface roughness and changed dimensions of these parts were measured by surface roughness measuring instrument and CMM. The model prepared based on these, gives the simulated results of wear varying from 27.3 µm to 87.8 µm shows a good correlation with actual measurement. In the last part of the work, the gear pump was removed from the system and worn-out parts were cut to prepare samples of the required sizes to observe under SEM. Morphology and texture results given by SEM help to study and predict the wear behaviour of system at particular operating conditions for condition monitoring. The combined approach of experimentation conducted here for quite a longer duration for such type of setup is the novelty of this work.
Experimentation and 2D Fluid Flow Simulation over an External Gear Pump Dhananjay G Adake, Nihal D Dhote, Mohan P Khond Journal of Physics Conference Series, 2023 In this work, the investigation’s goal is to conduct experiments and simulations on the existing gear pump test rig setup. The various parameters are set and observed in the first section of the investigation. Calculations are done using these numbers to obtain the other testing results. Another section simulates 2-D fluid flow over an external gear pump and contrasts the findings of the experiment with the flow rate and efficiency at various discharge pressures. This study provides a clear understanding of the external gear pump’s numerical analysis as well as its actual analysis. For each discharge pressure at the end, a prediction of pressure at various locations within the pump’s fluid domain was made.
Wear performance analysis and simulation of external gear pump Nihal Dhote, Mohan Khond, Sudarshan Chouhan Aip Conference Proceedings, 2022 As a kind of hydraulic power component, the external gear pump determines the performance of the entire hydraulic system. Gear pumps are subjected to various degradation such as wear which deteriorate the performance of the gear pump. The purpose of this research is to analyze the wear degradation of external gear pump under various operating conditions like speed, pressure and radial gap between gear tooth and casing. As wear affect the performance of gear pump, optimization of operating conditions on the performance of gear pump was studied. External gear pump is modelled in Fusion 360, and ANSYS CFD analysis was used for the simulation of volumetric efficiency under various operating conditions. The pump was simulated at different operating speeds and radial wear gaps.
Performance and ferrography analysis for determining the wear of an external gear pump Nihal Dhote, Mohan P. Khond, Shadab Sheikh, Abhishek D. Patange Journal of Physics Conference Series, 2021 The present work employs an experimental and analytical method to investigate the wear of an external gear pump. The first part of experimental method involves, running the gear pump on test rig for set number of working hours and the performance curves are plotted for studying any variation during the course of experiments. In the second part of experimental method the circulated oil was studied for any contamination. Contaminated oil is an indication of wear which is to be detected using ferrography. The gear pump therefore was run for maximum number of hours to study the variation in performance of gear pump due to wear during the running operation. The oil samples were collected after the pump has been run at a set discharge pressure for a certain number of hours. Wear was expected to occur to detect the presence of ferrous particles for checking whether the gear pump components have worn out after the operation. Direct ferrogram reading machine was used to detect small and large particle size concentration and based on this the wear severity index was found out analytically. Also the necessary conclusions using graphical trend are obtained between particle size concentrations and wear severity index with respect to time.
Performance analysis of semi-active suspension system based on suspension working space and dynamic tire deflection Jaydeep Funde, K. P. Wani, N. D. Dhote, S. A. Patil Lecture Notes in Mechanical Engineering, 2019 Vehicle handling and ride comfort are very important characteristics that influence the riding quality of the vehicle which depends on suspension. Semi-active suspension has the performance in between the active and passive suspension. In semi-active suspension system, damping coefficient changes according to the displacement and velocity of sprung and unsprung mass. There are various control strategies which decide requirement of damping coefficient for ride comfort and vehicle handling at various excitation frequencies. A fuzzy logic control strategy has been developed and compared with skyhook, groundhook, and hybrid control strategies. For the analysis, two degree of freedom quarter car model is used and simulated in MATLAB Simulink. The performance analysis has been done for two road profiles, namely bump and sine wave at 2.5 and 11 Hz frequencies, which are critical for ride comfort and vehicle handling, respectively. The results for body displacement, wheel displacement, suspension working space, and dynamic tire deflection have been compared for various control strategies. The analysis shows that skyhook control improves ride comfort for the results of maximum peak-to-peak body displacement with 23.91% improvement than that of the passive suspension model. While groundhook control improves vehicle stability for the results of maximum peak-to-peak wheel displacement and dynamic tire deflection which has improvement of about 44.81 and 12.7%, respectively, when compared with passive suspension model. Whereas hybrid control strategy improves the ride comfort as well as road stability depending upon the controller gain. Fuzzy logic control gives the optimized performance for ride comfort and vehicle handling for all the frequencies.
