In this paper, the new piezoelectric sensor array is introduced with the purpose of placing them within the gearbox to minimize the wave propagation path. Spline ridges are cut into this plate, a through-notch is cut perpendicular to the spline to model fatigue crack initiation, and tensile cyclic loading is applied parallel to the spline to propagate the crack. Here, to model how AE may detect fault propagation in a hollow cylindrical splined shaft, the splined section is essentially unrolled into a metal plate of the same thickness as the cylinder wall. The acoustic emission (AE) method is a direct way of detecting such active flaws, but its application to detect flaws in a splined shaft in a gearbox is difficult due to the interference of background noise and uncertainty about the effects of the wave propagation path on the received AE signature. Thus, early detection of flaws is required to prevent catastrophic failures. The splined section of the shaft is a critical and non-redundant element which is prone to cracking due to complex loading conditions. In many rotating machinery applications, such as helicopters, the splines of an externally-splined steel shaft that emerges from the gearbox engage with the reverse geometry of an internally splined driven shaft for the delivery of power.
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