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  • 1.
    Rastegari, Ali
    Volvo Group Trucks Operation, Köping, Sweden.
    Vibration analysis of machine tool spindle units2017In: World Congress on Engineering Asset Management WCEAM, 2017Conference paper (Refereed)
    Abstract [en]

    Machine tools cannot produce accurate parts if performance degradation due to wear in their subsystems (e.g., spindle units) is not identified and con-trolled. Appropriate maintenance actions delay possible deterioration and mini-mize machining system stoppage time that leads to lower productivity and higher production cost. Measuring and monitoring machine tool condition has become increasingly important because of the introduction of agile production and in-creased requirements for product accuracy. Condition Based Maintenance (CBM) techniques, such as vibration monitoring, are becoming a very attractive method for companies operating high-value machines and components. One of the most common problems of rotating equipment, such as machine tool spindle units, is the condition of bearings. Vibration analysis can diagnose bearing damage by measuring the overall vibration of a spindle or, more precisely, by high-frequency techniques such as enveloping. This paper focuses on the use of vibration analysis to monitor and analyse the condition of machine tool spindle units. The method is a case study at a manufacturing company in Sweden. CBM, using vibration moni-toring, is implemented on different types of machine tools. The results of the im-plementation, as well as a vibration analysis of a spindle unit and its cost effec-tiveness, are presented in the paper.

  • 2.
    Rastegari, Ali
    et al.
    Mälardalen University, School of Innovation, Design and Engineering, Innovation and Product Realisation.
    Archenti, A.
    KTH Royal Institute of Technology, Sweden.
    Online Vibration Condition Monitoring of Gas Circulation Fans in Hardening ProcessIn: International Journal of COMADEM, ISSN 1363-7681Article in journal (Refereed)
  • 3.
    Rastegari, Ali
    et al.
    Volvo Group Trucks Operations, Sweden.
    Archenti, Andreas
    KTH Royal Institute of Technology, Sweden.
    Mohammadsadegh, Mobin
    Western New England University, USA.
    Condition Based Maintenance of Machine Tools: Vibration monitoring of spindle units2017In: Reliability and Maintainability Symposium (RAMS), 2017, 2017Conference paper (Refereed)
    Abstract [en]

    Machining systems (i.e., machine tools, cutting processes and their interaction) cannot produce accurate parts if performance degradation due to wear in their subsystems (e.g., feed-drive systems and spindle units) is not identified, monitored and controlled. Appropriate maintenance actions delay the possible deterioration and minimize/avoids the machining system stoppage time that leads to lower productivity and higher production cost. Moreover, measuring and monitoring machine tool condition has become increasingly important due to the introduction of agile production, increased accuracy requirements for products and customers' requirements for quality assurance. Condition Based Maintenance (CBM) practices, such as vibration monitoring of machine tool spindle units, are therefore becoming a very attractive, but still challenging, method for companies operating high-value machines and components. CBM is being used to plan for maintenance action based on the condition of the machines and to prevent failures by solving the problems in advance as well as controlling the accuracy of the machining operations. By increasing the knowledge in this area, companies can save money through fewer acute breakdowns, reduction in inventory cost, reduction in repair times, and an increase in the robustness of the manufacturing processes leading to more predictable manufacturing. Hence, the CBM of machine tools ensures the basic conditions to deliver the right ability or capability of the right machine at the right time. One of the most common problems of rotating equipment such as spindles is the bearing condition (due to wear of the bearings). Failure of the bearings can cause major damage in a spindle. Vibration analysis is able to diagnose bearing failures by measuring the overall vibration of a spindle or, more precisely, by frequency analysis. Several factors should be taken into consideration to perform vibration monitoring on a machine tool's spindle. Some of these factors are as follows: the sensor type/sensitivity, number of sensors to be installed on the spindle in different directions, positioning of the vibration accelerometers, frequency range to be measured, resonance frequency, spindle rotational speed during the measurements, measurement condition, including the no-load condition with tool clamped or without a tool, measuring tools and technologies, automatic or manual run of measurement, measurement routine, warning limits, and data handling and analysis, among other factors. The aim of this paper is thus to address CBM and particularly the implementation in the manufacturing industries focusing on the use of vibration monitoring techniques to monitor the condition of the machine tools' spindle units. To conduct this study, a pilot project was followed in real time. The pilot project was performed at a manufacturing company in Sweden. The company's product is gearboxes for the automotive industry, with a production volume of approximately 135,000 units per year. CBM, by online and off-line condition monitoring, using vibration monitoring, has been implemented on different types of machine tools, including horizontal and vertical turning machines, multi-task milling machines and grinding machines.

  • 4.
    Rastegari, Ali
    et al.
    Mälardalen University, School of Innovation, Design and Engineering, Innovation and Product Realisation.
    Salonen, Antti
    Mälardalen University, School of Innovation, Design and Engineering, Innovation and Product Realisation.
    Bengtsson, Marcus
    Mälardalen University, School of Innovation, Design and Engineering, Innovation and Product Realisation.
    Wiktorsson, Magnus
    Mälardalen University, School of Innovation, Design and Engineering, Innovation and Product Realisation.
    CONDITION BASED MAINTENANCE IN MANUFACTURING INDUSTRIES: INTRODUCING CURRENT INDUSTRIAL PRACTICE AND CHALLENGES2013In: 22nd International Conference on Production Research, ICPR 2013, 2013Conference paper (Refereed)
    Abstract [en]

    This paper presents an introductory review of CBM practice applied in manufacturing industry, focusing the technical constituents within condition monitoring. The empirical base for the study is a case study of two major manufacturing sites in Sweden, complemented with a brief benchmark of data from two reference manufacturing sites from France and Brazil. The data from the main studies were collected by interviews and document analysis. The result indicates that there is a wide range within current practice of applying CBM. The implementations are dependent on process type (machining, assembly or heat treatment) and product type. By analysing the empirical data, gaps and challenges for implementing CBM in industry are presented, primarily focusing condition monitoring within manufacturing industry. The paper concludes with a discussion on possible future trends and research areas, needed to increase the industrial use of CBM.

  • 5.
    Rastegari, Ali
    et al.
    Mälardalen University, School of Innovation, Design and Engineering, Innovation and Product Realisation.
    Sasha, Shahbazi
    Mälardalen University, School of Innovation, Design and Engineering, Innovation and Product Realisation.
    Bengtsson, Marcus
    Mälardalen University, School of Innovation, Design and Engineering, Innovation and Product Realisation.
    Condition-based maintenance effectiveness from material efficiency perspective2017In: International Journal of COMADEM, ISSN 1363-7681, Vol. 20, no 1, 23-27 p.Article in journal (Refereed)
    Abstract [en]

    This paper addresses the controversial gap between the environmental perspective and the cost perspective in a manufacturing context. The results of an empirical study on the heat treatment and phosphating processes performed by a manufacturing company indicate that implementing condition-based maintenance contributes not only to cost savings by preventing production losses and reducing equipment downtime but also to a more efficient use of resources by avoiding the generation of scraps and material wastage.

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