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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12 13. Definitions and Objectives Types of Lubrication Dynamic Viscosity Bearing Characteristic Number Stable & Unstable Lubrication Hydrodynamic Lubrication Design Considerations Heat Balance-Self-Contained Bearings Clearance Pressure-Fed Bearings Loads and Materials Boundary lubrication Types of Journal Bearings
QUIZ4
1.
Rolling-contact bearings (anti-friction bearings, rolling bearings). In the rolling-contact bearings the load is transmitted by rolling rather than by sliding. bearings). In journal bearings, the load is transmitted by sliding and the problem of this class of bearings is essentially a lubrication
Journal Bearings:
Among applications:
Types of Lubrication
1. Hydrodynamic Lubrication (HDL)
(a) Full, thick Fluid film lubrication - surfaces separated by bulk lubricant film; Film conditions required for lubrication.
4. Elastohydrodynamic
For rolling contact (gears, rolling bearings)
5. Solid Film
Extreme Temperatures (Graphite or Molybdenum disulfide))
(HDL)
Viscosity
Shear Stress
F du = = A dy
is absolute or dynamic viscosity
c=
(lbf.s/in2 or reyn. In ips system and Pa.s in SI system) du/dy is the rate of shear or velocity gradient If rate of shear is constant: du/dy = U/h With h= c (clearance)
Fig. 12.1
F U = = A h
U = c
Petroffs Law
Petroff used a concentric shaft to define a group of dimensionless parameters That allow the prediction of an acceptable coefficient of friction.
U c
2 rN c A = 2 rl
Ts = (A) r ;
2
4 2 r 3lN Ts = 2 ( ) r l = c
Friction torque
T f = fWr = f (2 r lP )r T f = Ts
W 2rl N r 2 = 2 P c ; P=
N = P
2 r c
r f = 2 2 S c
a
1 2
f = 0.001-0.005 Similar to precision BB
1. e: eccentricity 2. h0 minimum film thickness 3. = e/c = eccentricity ratio 4. bearing angular length
Assuming pressure varies in x-direction only (no leakage) Assuming Velocity varies in x & y directions
Fx = dp p + dx dydz pdydz dxdz dx + + dxdz = 0 dx y dp = dx y
(1)
u=
1
2
dp 2 y + C1 y + C2 dx
(4)
h dp 2 dx
(5)
u =
dp 2 dx
(y
hy
)+
(7 )
U h
(6 )
Q = udy
h 0
Uh h 3 dp = 2 12 dx
Incompressible flow:
dQ =0 dx
(8 a)
(12 10)
3 d h dp dh = 6U dx dx dx
The above is the Reynolds Eq. For one-dimensional flow. Considering Leakage (2-D):
3 h3 p h p dh = 6U + dx x z z x
(12 11)
r f c
r 2 = c
N
P
(12 12)
Design Considerations
Two groups of variables in the design of sliding bearings (eq:12.12) r N r A- The independent variables: f = (12 12) c P 1. The viscosity , c 2. The load per unit of projected bearing area, P (unit Load) 3. The speed N=NJ (see equation 12-13) 4. The bearing dimensions r, c, and l (important l/d) B- The dependent Variables or performance factors: 1. The coefficient of friction f 2. The temperature rise T 3. The volume flow rate of oil Q 4. The minimum film thickness ho
2
The first (A) are somewhat under designer control and the second (B) are not. Certain limitations should be set for variables B and A varied to satisfy them
1. The value of the important parameter l/d is taken between 0.25 and 1.5. Values up to 2 and 3 were used in earlier designs. Nowadays, the value of l/d is confined between 0.25 and 0.75. Short bearings are preferred when shaft deflections and misalignments are expected. 2. The nominal value of clearance ratio r/c can be taken approximately as:
1000 for precision bearings when 25<d<150 mm 500 for general machinery 250 for rough machinery The choice of the values of r/c depends on the tolerances and surface roughness of shaft and bearing.
h0 = 0.00025d
(in) or
(in) (mm)
4.
5. 6.
The outlet temperature of the oil should be kept below 250F (121C). A value around 70C (160F) is usually specified as the average operating temperature. Starting unit load Pst=Wst/ld is kept below 300 psi Design factor on starting load should be at least 2.
loss
T 1 Qs = C p Qs + C p Q Q s T = C p Q T 1 2 2 Q
(a )
loss
J C p T
Equating (a) to (b)
With = 0.0311 lbm/in3 & Cp = 0.42 Btu/lbm.F for petroleum lubricants and J=9336 lbf.in/Btu
4 P
9 . 70 T F
Ppsi
fr / c (1 0 .5 Q s / Q )[Q / (rcNl
)]
(12 15 )
1.65
Problem # 12-12 Given: d = 2.5 in, b = 2.504 in, cmin = 0.002 in, W = 1200 lbf, SAE = 20, Required (see list)
T1 = 110F,N = 1120 rev/min, and l = 2.5 in.
Solution: to find any of these performance factors we need to have the bearing characteristic number: S.
S
r = c
2 N av = P
1 . 25 . 002
2 18 . 67
av
1200 2 .5 2 .5
= (625
)2
18 . 67 av = 3 . 8 10 4 av 192
Procedure: (good for IPS and SI system) 1. For a first trial assume T = (General) 20 80 F (10-50C) For our case take T = 40 F 2. Tf =130 F
To find average viscosity (From Fig. 12-11; 12) we need to have the average operating film temperature Tf (Eq. 12-14): T f = T1 + 2T
Problem # 12-12
3. 4. 5. Find av = 3.8 reyn (From Fig. 12-11; 12) using Tf = 130F Calculate S = 3.8x104x3.8x10-6 = 0.144
or TC using 12-18 or Fig 12-23; 24 with S=0.144 and l/d =1 9 .70 T = 1 .3 T = 192 1 .3 / 9 .70 = 25 .7 o F F
F
Calculate TF
Ppsi
6. 7.
Recalculate Tfcal = 110+25.7/2122.85 F Compare Tfcal to Tfassum if |difference| less than 6 F or 3 C Recalculate, For our case Tfassum -Tfcal = 130-122.85= 7.15 >6 F need to re-iterate:
1 2 3 4
assume T =30 F
Tf = 125F av 4.3 reyn 5 6
TF 27 F
Tfcal = 110+27/2123.5F Tfassum -Tfcal = 125ACCEPT: Tf = 125F or Tf = 7
S 0.163
123.5=1.5<6 F (125+123.5)/2= 124.25 F
Problem # 12-12
av = 4.3 reyn (From Fig. 12-11 for oF; 12 for oC) using Tf = 125F yielding S=0.163 a) Using Fig 12-16 with S=0.163 and l/d =1
h0/c = 0.49 h0 = 0.0098 in Using Fig 12-17 = 56 b) e= c- h0 =.002-.00098 = 0.001in. or using Fig. 1216 =e/c = 0.5 e = 0.001 in. c) f :Fig 12-18 (r/c)f= 4 f= 4/625=0.0064 d) Power loss: H=(2TN)/(778x12)= (2fWrN)/778x12=
H = 0.121 Btu/s =436 Btu/hr H = 126 j/s=453 KJ/hr
Problem # 12-12 e)
Using Fig 12-19 with S=0.163 and l/d =1 Q/rcNl = 4.15 Q = 4.15x1.25x0.002x18.67x2.5=0.48 in3/s Using Fig 12- 20 Qs/Q=0.61Qs = 0.29 in3/s Using Fig 12-21 P/Pmax = 0.44 Pmax = 192/0.44=436 psig Using Fig 12-22 Pmax = 18 & p0 = 82 See part (a) Tav = 125F T2= 110+30=140 F
NOTE: In cases where l/d curve is not available the interpolation equation (12- 16) may be used when necessary.
f) g) h) i)
Sample problem on Design of HDL Journal Bearings (to be solved during help session) Design a journal bearing to carry a radial load of 1500 lb while the shaft rotates at 850 rpm. The shaft stress analysis determines that the minimum acceptable diameter at the journal is 2.10 in. The shaft is part of a machine requiring good precision. Power loss in the bearing should not exceed 1% of the 15 hp driving power.
Procedures for design of oil lubricated journal bearings A- Full-film (Hydrodynamic) Lubrication
Step1: Often, the shaft diameter at the bearing is determined by strength and deflection analyses. If the shaft diameter is not known Table 12-5 or Table 288 of the Standard Handbook of Machine Design can be utilized to get a rough estimate of the unit load P=W/ld (with W being the applied load). This value is combined with the value of l/d (ratio of bearing length to bearing diameter), determined in the next step, to find the dimensions of the bearing.
Its value can be compared to the input power to take a decision concerning f and h0.
Step10: Select a suitable bearing material from Table 12-5 [3,4] or from Tables 28-2 to 28-4 of the Handbook [5]. Unit load, maximum operating temperature and conditions should be used as criteria for material selection.
Self-Contained Bearings
Pillow-blocks or pedestal bearings are used for: Fans, Blowers Pumps and small motors
Self-Contained Bearings
Two general types of lubrication: 1) Oil-Ring and 2) Oil Bath Since the warm lubricant stays within the bearing housing; it should be designed such that the heat generated by friction is dissipated. As seen above the heat generated (in Btu/s) by friction can be estimated:
H gen
2 TN 4 Pr lNc fr = = c J J
Where J= 9336 in.lbf/Btu
(b )
Or in (hp)
H gen
The heat to be dissipated & surface temperature of housing (=Tbearing) are respectively:
(T f T ) 1+ T f + T Tb = 1+
loss
h CR A
Tf is the average film temperature which is unknown and found by trial and error to satisfy Hgen=Hloss as in the following example. See also (Eq. 12-20) for Tf
Clearance
Among the independent variables under designers control, clearance is the most difficult to hold accurate during manufacture and It may also increase during service because of wear. When selecting a clearance for a JB a number of performance variables and expected in service wear should be taken into account.
Bearing Noisy+ h0 decreases
Clearance
Table 12-3: Max., Min. & Average Clearances for 1.5 in. dia. JB based on fit
Clearance
Temperature limits for mineral oils
O2 insignificant
Pressure-Fed Bearings
At high bearing loads and high temperature: turbo machinery, car engines, Elect. Subm. Pumps, etc Lubricant is supplied at a supply pressure Ps through supply hole drilled opposite to load bearing area side.
Pressure-Fed Bearings
Unit load
W /2 W = 2 rl ' 4 rl ' l w l'= 2 P =
( 12
23
Velocity Profile
u=
ps (c 2 4 y 2 ) 8l '
(12 21 )
Pressure-Fed Bearings
Centrally located full annular groove
Pressure-Fed Bearings
Natural circulation of oil Pressure-Fed lubricant
Velocity
u=
1 dp 2 U y y hy 2 dx h
(6)
u=
(12 21 )
u max
Side-Flow
p rc (1+1.5 Qs = 3l '
s
(12 22)
Unit load
P=
W 2rl
P=
(12 23)
(12 24 ) (12 25 )
An eight-cylinder diesel engine has a front main bearing with diameter 3.5 in. and length 2 in. The bearing has a central annular oil groove 0.250 in. wide. It is pressure-lubricated with SAE 30 oil at an inlet temperature of 180F and at a supply pressure of 50 psi. Corresponding to a radial clearance of 0.0025 in, a speed of 2800 rev/min, and a radial load of 4600 lb, find the temperature rise and the minimum oil-film thickness.
(12 24)
Problem # 12-16
1. 2.
3. 4. 5. 6.
Find av = 1.4 reyn (From Fig. 12-12) using Tf = 195F Calculate S = 0.0426 Use S = 0.0426 and l/d = to find = 0.93 from Fig. 12-16 & (r/c)f = 2.2 from Fig. 12-18 Calculate TF
6. 7.
ACCEPT: T = 30 F
Problem # 12-16
Using Fig 12-16 with S=0.0426 and l/d =1/4 h0/c = 0.07 h0 = 0.000175 in Trumplers Criteria satisfied? 1) h0 0.0002+0.00004(3.5)=0.00034 in not satisfied? 2)
4.
Non-Metallic Materials (Table 12-6) such as Wood, Rubber, Carbon Graphite, Derlin, Teflon, Nylon Most have low thermal conductivity.
Boundary Lubrication
thin-film, Olite, Oiles, bushed pin In certain applications boundary lubrication should be designed for (see your lab manual and earlier notes and example for the procedure of boundary lubrication design). Boundary lubrication should be expected for slow speeds (start ups and shut downs) : U<10 ft/min (0.05 m/s).. In boundary lubrication the bearing performance depends essentially on boundary film. The coefficient of friction is reduced by using animal and vegetable oils containing fatty acids that stick to metal surfaces.
Materials for Boundary (thin-film, boundary friction, oilite, oiles and bushed pins)-Lubrication
To minimize metal-to-metal contact in boundary lubrication: Mix animal or vegetable oils with lubricant Use porous metallic materials (Table 12-7) Use non-metallic materials (Table 12-8) wear rate = w = f f K ( PV ) 1 2 Use indented bearings t
(12 27)
Design a boundary lubricated plain-surface bearing to carry a radial load of 2.5 kN from a shaft rotating at 1150 rpm. The nominal minimum diameter of journal is 75 mm.
Radial
Thrust
Journal Bearings
Types of bearings
Plain Bearings
Journal Bearings
Bushes
Polymer Bearings
Types of Bearings
Radial Journal Bearings for Pinion Shaft in Gear Box for GE Turbine ESCOSA-DAMMAM
Types of Bearings
Housing for Gear Box showing Radial Journal Bearing Supports
Types of Bearings
Radial Journal Bearings for Pinion Shaft in Gear Box for GE Turbine