CAD OF HYDRODYNAMIC JOURNAL BEARINGS Abdethamid Gomaa, Mohamed M. EIMadany and Abdul Mohsen Albedah Mechanical Engineering Department College of Engineering, King Saud University P.O. Box 800, Riyadh 11421, Saudi Arabia ABSTRACT ‘The design process of a journal bearing involves reading of various charts and tables of numerical values, causing time consuming and less accurate results. A computer aided design (CAD) procedure is developed using an integrated metghodology for designing full hydrodynamic journal bearings of finite length. The relevant theoretical and empirical data are collected and presented in appropriate formats. A database containing the design variables of load per unit of projected bearing area, and bearing clearance in industrial applications, needed in the bearing design is derived. The performance variables including temperature rise, clearance, minimum. film thickness, and stability indicate how well the bearing is performing, Certain limitations on their values are imposed, using empirical {uidelines, to assure satisfactory performance. Design optimums are based on maximum load, which is load-carrying characteristics and minimum friction, which is a function of the departure from thick- film relationships, Keywords: Computer aided design, hydrodynamic journal bearings, optimum bearing design. 1 INTRODUCTION Computer aided design is computer software that supports design activities. Well-developed computer software has already revoltionized the analysis of structures. The situation, however, is quite different in the design of mechanical systems. While the potential for computational techniques in this field is at least as great as for structures, development has lagged behind, The objective of this project is to present basic methods for the computer formulation solution of full journal bearings, gineering design is a complex problem-solving activity. In essence it is an iterative, decision 1B process whereby sciemtfic and technological information is needed to produce engineering systems, devices, products and components in order to satisfy some human need (1, 2]. Design involves four distinct aspects of engineering and scientific endeavour. The problem definition from a “fuzzy” array of facts into a coherent statement of the questions; the creative process of devising a proposed physical embodiment of solutions; the analytical process of determining whether the proposed solution is correct or rational; and the ultimate check of the fidelity of the design product to the original perceived need, Tt would be ideal if CAD software could be used to suppor all phases of the design process - from product specification development through conceptual design to product design, Unfortunately, this is, not the case, because (i) existing computer tools need a very refined representation ofan object on ‘which to operate, and thus are poor at handling the abstract information used in the conceptual design phase, and (i) computers are primarily evaluation tools. Techniques for general concepts and products are not well enough understood to be codified on a computer, except in very limited areas [3, 4]. Therefore, computer aided design primarily solves the solution design problems which involve direct selection of standard systems or components. Neverthless, the essence of the objective of computational methods is to make maximum use of digital computer power for rapid and accurate data manipulation and numerical computation, fence releiving the engineer of tedious and error calculations that therefore have been carried out manual or with computer programs. In addition, the manual methodhas several limitations: (a) some candidate solutions may not be considered, (b) the process depends totally on the designers, and (c) the process is time consuming 2 BACKGROUND Most industrial turbomachines are designed to use some type of hydrodynamic bearings. In journal bearings, the fluid support pressuce is generated entirely by the relative motion between the journal and bearing and depends on the viscosity ofthe lubricating fluid. The fluid supply pressure need only be high enough to maintain a copious supply of lubricant in the load-supporting clearance around the journal. The mechanics of generating hydrodynamic film pressure can be described as follows. The lubricating Muid is pulled by viscous shear into the converging wedge produced by off-center displacement of the journal. As the fluid is pulled into the converging wedge, its pressure is raised Conversely, the fluid pressure decreases as the viscous shear pulls it out into the diverging wedge down siream from the point of mininum film thickness. The effect of distribution of hydrodynamic pressure around the journal is to produce a force which reacts the applied load, Journal bearings are termed full bearings when the bearing surface completcly surroundings the Journal. ‘They. are called partial bearings when the bearing surface extends over only a segment of the circumference, generally, 60°, 120°, and 180° ‘The mathematical theory of hydrodynamic lubrication is based upon Reynolds’ work [5]. ‘The differential equation governing the pressure in the lubricating film is called the Reynolds’ equation, which has been solved subject to three types of circumferential boundary conditions. These boundary conditions are Sommerfeld, Gumbel, and Swift-Stieber {6} 3. FUNCTIONAL DETERMINATION Functional requirements are derived from the overall design goals such as maximum load, minimum friction, higher efficiency, etc. These requirements ultimately arc translated into design criteria which potential candidate journal bearing must meet in order to be accepted. Selection of these criteria is probably the most important step in. the design process and depends largely on the expertise and the experience of the designer. In the design of journal bearings, onc may distinguish between two groups of variables [7]. The first ‘group consists of prescriptive variables that may be controlled by the designer. They include the load per unit of projected bearing area (P = Wild), the viscosity y, the lubricant inlet temperature Ti the speed N, the allowable bearing range of clearance, the bearing dimensions d, /, cand fj; (d = diameter, / yearing arc) ‘The second group contains the dependent variables such as the temperature rise AT, the minimum film thickness hi, the cooficient of friction f, the flow of oil Q, the side leakage Q,, the eccentricity ratio e, the attitude angle 4, the maximum pressure Py, the position of maximum film pressure @ p. the + does not have position at which film terminates p, , and the power loss - see Fig. 1. The desig direct control over these variables, but he could impose certain limitations 10 assure satisfactory performance. Therefore, the fundamental problem in bearing design is to define satisfactory limits (unctional specifications) of the second group of variables and to decide upon values for the first group ‘such that these limitations are not exceeded.4 REJECTION FUNCTIONS AND CRITERIA ‘The rejection function of a rejection criterion is the test which is applied to a solution to determine whether the solution passes the rejection criterion under consideration. Solutions which pass the test are retained for application of additional rejection criteria From practical experience in bearing design, a number of design rules have emerged that provide general guidance in choosing bearing dimensions and acceptable operating conditions. These design rules constitute the different rejection criteria (or constraints) which are employed to screen out ‘unacceptable solutions. 4.1 Heat generation - Temperature rise. ‘The oil supply is usually greater than the oil circulation in the bearing in order to keep exit temperature low. Usual design temperature difference AT between oil supply and return are in the range 0°C to 15°C and they seldom exceed 20°C. Therefore, in this study, the limit on exit temperature is set at orc. 4.2 Clearance ratio (cir) ‘The bearing performance is particularly sensitive to changes in the clearance ratio. The clearance ratios are_usually within the range of 001 10.0005. Asa standard practice, Vogelpobi [8] suggests c/r 1000 + 4 v'®, where v is inns. In this study, an option is offered in which the calculations are performed for a range of clearance ratios and the resulls tabulated, The clearances used in industrial applications, Table 1, are stored as database which may be used by the designer. This constraint may be changed or modified by the user. 43 Mi imum film thickness (h,) Surface finish of journal and bearing, production tolerances, and the effects of possible contaminants in the oil supply must all be considered in the design of the journal bearing. For small bearings (less than 50 mm diameters) having high quality surface finish and running at slow to medium speeds, lpia is designed to be not less than about 2.5 jum, Trumpler [9] suggested minimum film thickness (mm) greater than or equal 10 0.005 + 00004, where d is in mim, This relationship should be used with a safety factor of 2, In the program, h, is calculated and checked against the recommended value by ‘Trumpler, 44 Rotor-bearing stability ‘At high speed operation, rotors supported on fluid film journal bearings may develop an instability known as oil whip. This instability occurs at approximately twice the first eritical speed and manifests itself by a sudden increase of the whirl amplitude of the rotor, The source of instability is the hydrodynamic forces of the bearing fluid film. The fluid film forces, under certain operating conditions, are capable of sustaining a self-excited vibration by transferring energy from the rotor rotation into a whirling motion of the shaft The stability of full journal bearings with a fixed, rigid, and perfectly balanced rotor under the assumption of light initial impact and plane-motion has been investigated by Bodgley and Booker (10}. The results are_presented for shor, long-, and finite-length bearing approximation, Fig. 2. Itis clear from the figure that cither © must’ be > 0.83 or dimensionless , should be < 2.33 forthe stability of finite-length full journal bearings. This constraint may be modified by the user.Fig.1 Polar diagram of film-pressure distribution. 30 1 20 ——. - — short ! Long, t —— Finite ! 10 t H cs 8 : 2, 1 = t 5 ; ? instable 1 re Unstabl 2 | 7 > ge _ See 2 — Stable 1 = 0.0 0.2 0.4 0.6 0.8 1.0 Fig.2 Instability threshold curves for full journal bearings for indicated assumptions after small initial-velocity disturbances (10). Table 2. Unit load P for journal bearings. pplication Diesel engines 1. Main bearings ‘Table 1. 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DESIGN METHODOLOGY ‘The database required for the design of full journal bearings for the maximum load (W) and the ‘minimum friction (f) is collected from References [6, 7, 11, 12]. For the design of journal berings, Boyd and Raimondi [13, 14], used an iteration technique to solve Reynolds’ equation on digital computer. They published their work in three parts which contain 45 detailed charts and 6 tables of ‘numerical information for the design of bearings with slendemess ratios (/d) of 0.25, 0.5, and 1 for both partial and full journal bearings. Part III contains data forthe infinity long bearing (I/d = c). IN (ir “(9 w re In dealing with the charts, once S is known, all the performance variables are obtained from the charts The values of the desired performance variables at different Md ratios other than 0.25, 0.5, 1, and co can be found with the help of the following equation suggested by Raimondi and Boyd [14] (96-D--e-Vl-Il-Ds o-Ioae(B-B-Zn] where y is the desired performance variable and the subscript of y is the Md rtio at which the variable is being evaluated. Yd SA. Viscosi ‘Temperature Relationships For computer applications, the viscosity-temperature function is expressed by the relationship [6] b H= Ho ool as Ja ® ‘The constants ji, and b for different SAE grade are given below: SAE Oil Grade Pas c SAE 10 0.108941 25.277 SAE 20 00937720 688.6666 — SAE 30 00972185 738.2777 SAE 40 0.0834295 801.3333, SAE SO 0.1172150 820.8888 SAE 60 01289365 851.11116 5.2 Design Process ‘The architecture of the proposed design methodology is explained as follows: The main window has four command-buttons tabled: Database, Design data, start, and Exit, Fig. 3 ‘The database, Fig. 4, contains two tables. Table I gives the allowable range of clearance for several bearing industrial applications, while Table 2 gives the unit load P in current use for journal bearings (1 ‘The design data represents the input module. The functional and specifications needed for this module for the design of full journal bearings for maximum load or minimum friction are given below (see Fig.3): a. bearing load W(KN), b. shaft speed N(rpm) c. shaft diameter (mm), d. lubricant inlet temperature TwCO) . minimum and maximum values for I ratio with associated increment. I could be determined from the range of recommended bearing unit load (default) bearing unit load P= W/ld (MPa). There are two options: the user may enter the selected values of P or select range of values depending on the application from a menu (Table 2) 8. specific oil grade or all the six grades. hh. range of clearance, The computer will select a range depending on the bearing industrial application (default). This could be override by the user. The design process of the hydrodynamic journal bearing is modelled as a sequence of stages. Each stage is corresponding {0 one constraint to be satisfied. In order to move from one stage to another, an ‘operation is performed. The operation may consist ofa set of knowledge bases, a group of nules and/or solving a set of equations. The database used by each operation is written into a file, and at the end of ‘each stage an internal database consisting of all partial feasible solutions is created and is written into a new file, At the end of each stage, the program may report the number of solutions available at that stage with the option of printing them. In case there is no solution, the constraint at that stage can be ‘modified by the user and the program can be rerun. 6 EXAMPLE The program is used to design fll journal bearings for maximum load. The input specifications are {11}: a gear-reducer shaft with bearing load = 4.45 KN, spzed of shaft = 1200 rpm, lubricant inlet temperature = 60°C, shaft diameter = 80 mm, il-grade=all six oil-grades, and bearing industrial application = elecric motor and generator practice, Fig. 5. In this example, all the design alternatives satisfy temperature rise constraint, and therefore at the end. of stage 1, there are 36 solutions, Fig. 6. Thirty one ofthese solutions are discarded because they do not fulfil the constraint of industrial application for clearance. All the remaining five solutions satisfy both minimum film thickness and stability constraints, Fig. 7 7 SUMMARY ‘An integrated design methodology for the design of full hydrodynamic journal bearings is developed. The architecture of the CAD consists of several stages. The required functional specifications and decision-criterion are entered first, then the design solutions of successive stages are examined for any violation of the design constraints, The program solves a bearing design problem of any value of lid ratio, SAE 10, 20, 30, 40, 50 and 60 oil-grade, and decision criterion as maximum load and minimum, friction. The programming language is visual Basic. Itis intended to device an appropriate utility function for evaluating the design solutions.eplay solutions that pase Constsints: Toute tomporatne 53. Min fn thicknees Cont 4 Stauty © Constant 1 © Constante 142 links 120904 e209 (own, (recta ee] Fig.3 Main window Fig Database construction eee ern eine 4. Stabaty test pDesiga criterion ————— [5 Design Dats ___ Sewing oad) RE] Vara = en Seat amcte (en) BT} tncement fT Design constraints imine 7 1, Dutt temperature) FTE diya Riga Ry Mare dna yn°3} so] Spestic heat U/kg | [F760 Load/erojected area(MPa) rs @ Nainm load G Miniaue filion [Gexeascertonings | and design criteria[05 Design of Jounal Deming SSS] a O42 O50 40 20 8848 0.079 0.345 0.477 9.000 4.000 050 40 30 8843 0.035 0.345 0477 9.000 4.000 0.50 40 40 8848 0.040 0.345 0.427 9.000 4.000 0.50 40 50 8848 0.051 0.345 0427 9.000 4.800 0.50 40 60 8348 0.099 0.345 0427 9.000 4.800 0.60 48 10 81.10 0.031 0.302 0461 7.686 4.644 60 48 20 81.10 0.036 0.302 0.461 7.656 4.644 ogo 48 30 81.10 0.043 0.302 0.461 7.656 4.644 060 40 40 81.10 0.080 0.302 0.461 7.656 4.644 ogo 4a 0461 7.656 4.644 0.461 7.656 4.644 Number of solutions = 36 Display soltions that pass: aggre Constiaints 5 4 _ @ Constant T) 1" Oultet temperature © J 2 Clearance © Constraints 142 Besa 3 Min: film thickness (> Constraints 14243 Sa 4. Stability Ee j C Constants 12134! SG GIBBS ie (CoRR AEH A27O) 0.90 72 50 70.67 0.102 0.224 O81 3.349 4.217 0.593 0.9072 60 70.87 0119 0.224 O82t 5.349 4.217” 0.593) 1.00 80 50 69.19 0.113 0.208 0.533 4.900 4.100 0.560) 1.60 80° 60 69.19" 0.133 0.208 0.533 4.900 4.100 0.560) —— — = — 2 Number of solutions = 5 [Display solutions that pass EE Constraint: constraint 1. Outlet temperature Constiaint 1 (Dess] 2. Gearanoe 6 Consteaints 162 3. Min. film thickness Constraints 142 | haa A. Stability Oo [ees Constraints 1e2+5¢4| (ERSTE Fig.7 Alternative design solutions passing all the constraintsREFERENCES 1. Dieter, GE, Engi Singapore, 1991 2+ Ullmon, D.G., The Mechanical Design Pracess, McGraw-Hill, In., 192 3- Dyme, C.L, ed, "Applications of Knowledge-Based Systems to Engineering Analysis and Design", ‘ASME, WAM, Nov., 1985. 4+ Akagi, S., and Fujita, K., "Building on Expert System for Engineering Design Based on the Object- Oriented Knowledge Representation Concept", ASME, Journal of Mechanical Design, 1990, Vol. 112, pp. 215-222. 5- Reynolds, O., “Theory of Lubrication, Par I, "Phil. Trans. Roy. Soc., 1886, London 6- Shighey, JE, and Mischke, CR. B Mechanical Desig ‘McGraw-Hill Pub. C., New York, 1990 7- Shigley, LE., and Mischke, CR., Mechanical Engineering Design, McGraw-Hill Int Fifth Edition, Singapore, 1989 8- Vogelpohl, G., Betriebssichere Geitlager, Berlin, Springer, 1958, 9- Trumpler, P., Design of Film Bearings, New York, Macmillan, 1966 10- Badgley, RH, and Booker, JF, "Turborotor Instability: Effect of Initial Trans Motion’, Journal of Lubrication Technology, 1969, pp. 625-633 11- Juvinall, R.C., Fundamentals of Machine. Component esis 1983. 12-Dimarogonas, A., Computer Aided Machine Design, Prentice Hall, New York, 1988 13- Boyd, J., and Raimondi, A.A., "Applying Bearing Theory to the Analysis and Design of Journal Bearings, Part I and II, J. Appl. Mechanics, 1951, Vol. 73, pp. 298-316. 14- Raimondi, A.A., and Boyd, J," 4 Solution forthe Finite Journal Bearing and lis Application to Analysis and Design, Part 1, Il, and HI", Trans. ASME, 1958, Vol. 1, No.1, Lubrication Science and Technology, Pergamon, New York, pp. 159-209, net Design = A Materials and Processing Approach, McGraw-Hill Int xs! Workbook, nt on Plane John Wiley & Sons, New York,