MSRSAS - Postgraduate Engineering and Management Programme - PEMP

Module Code Module Name Course Department

AEL 501 Tribology & Heat transfer M.Sc. [Engg] in Machinery design. Mechanical and Manufacturing Engineering.

Name of the Student Reg. No Batch Module Leader

Prabhakar.P BAB0911001 Full-Time 2011.

Prof. Mr.Balappa.B.U

M.S.Ramaiah School of Advanced Studies

Postgraduate Engineering and Management Programmes(PEMP)
#470-P Peenya Industrial Area, 4th Phase, Peenya, Bengaluru-560 058 Tel; 080 4906 5555, website: www.msrsas.org

POSTGRADUATE ENGINEERING AND MANAGEMENT PROGRAMME (PEMP)

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ASSIGNMENT

Declaration Sheet Student Name Reg. No Course Batch Module Code Module Title Module Date Module Leader PRABHAKAR.P BAB0911001 MACHINERY DESIGN FT11 MMD504 TRIBOLOGY AND HEAT TRANSFER to Prof. Balappa.B.U Batch Full-Time 2011

Extension requests:
Extensions can only be granted by the Head of the Department in consultation with the module leader. Extensions granted by any other person will not be accepted and hence the assignment will incur a penalty. Extensions MUST be requested by using the Extension Request Form, which is available with the ARO. A copy of the extension approval must be attached to the assignment submitted.

Penalty for late submission

Unless you have submitted proof of mitigating circumstances or have been granted an extension, the penalties for a late submission of an assignment shall be as follows: Up to one week late: Penalty of 5 marks One-Two weeks late: Penalty of 10 marks More than Two weeks late: Fail - 0% recorded (F) All late assignments: must be submitted to Academic Records Office (ARO). It is your responsibility to ensure that the receipt of a late assignment is recorded in the ARO. If an extension was agreed, the authorization should be submitted to ARO during the submission of assignment. To ensure assignment reports are written concisely, the length should be restricted to a limit indicated in the assignment problem statement. Assignment reports greater than this length may incur a penalty of one grade (5 marks). Each delegate is required to retain a copy of the assignment report.

Declaration
The assignment submitted herewith is a result of my own investigations and that I have conformed to the guidelines against plagiarism as laid out in the PEMP Student Handbook. All sections of the text and results, which have been obtained from other sources, are fully referenced. I understand that cheating and plagiarism constitute a breach of University regulations and will be dealt with accordingly.

Signature of the student Submission date stamp

(by ARO)

Date

Signature of the Module Leader and date

Signature of Head of the Department and date

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Abstract
____________________________________________________________________________ Tribology is the recent developed technology were but the concepts of the Tribology is been used from thousands of years back Tribology deals with the relative motion of interacting surfaces. It also includes the concepts of lubrication, control of friction and wear. The science and technology of relative motion includes the concepts of bearings includes the selection of bearings, study of lubrication and wear takes place in bearing, Lubrication in bearings and possible wear control in bearings. In the Part-A assignment is about the bearing selection nowadays bearings are commonly used in the all the machineries. The debate is about the selection of the bearing were the bearing selection depends on only the load carrying capacity or some other factors also such as lubrication, bearing type, bearing clearance etc needs to be considered to operate the bearing effectively and also to improve the efficiency of the bearing. In Part-B assignment is splited into three divisions the first two divisions is about the selecting any two construction machines and analyzing about the bearing used in the machine. For this part a wheel loader is selected and grease lubricating journal bearing is analyzed. The second one is hydraulic piston pump is selected which is commonly used in construction machines for the actuation of telescopic cylinders in which the taper roller bearing is analyzed. The analysis is based on the type of bearing selected in the machine, role of bearing in the machine, load carrying capacity of the bearing, details of mounting, lubrication, wear is being analyzed. The third division of Part-B assignment is the calculation of partial journal bearing were the load carrying capacity of bearing, coefficient of friction and maximum pressure in the oil is to be calculated. In Part-C assignment is the calculation, were the inlet position is given for the journal bearing. The pressure distribution in the lubrication in 360 is calculated and crosschecking with the inlet position as a tribologist point of view comments on the current inlet position weather is there a possibilities of the leakage and to suggest the suitable inlet position for the journal bearing. Were the pressure distribution curve is plotted to analyze the inlet position provided in present and the alternative remedies for leakage is given.

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Contents
____________________________________________________________________________

Contents
Facing Sheet i Declaration Sheet ......................................................................................................................... ii Abstract ....................................................................................................................................... iii Contents ........................................................................................................................................iv List of Tables ................................................................................................................................vi List of Figures ............................................................................................................................ vii List of Symbols ......................................................................................................................... viii 1.0Introduction .............................................................................................................................ix 1.1 The various factors to be considered in bearing selection: .....................................................ix 1.1.1 Environmental and operating condition (Areas of application): .........................................ix 1.1.2 Load carrying capacity: .......................................................................................................ix 1.1.3 Considering the bearing........................................................................................................ x 1.1.4 Considering the precision of bearing: .................................................................................. x 1.1.5 Considering the bearing clearance (Eccentricity): ............................................................... x 1.1.6 Considering the lubrication method: .................................................................................... x 1.1.7 Installation and disassembly:................................................................................................ x 1.2 Case study[1]: .......................................................................................................................... x 1.3 Conclusion: ............................................................................................................................ 11 2.A Introduction to grease lubricated journal bearing[2]: ............................................................. 4 2.A.1 Loading unit of wheel loader:.............................................................................................. 5 2.A.2 Lubrication methods: ........................................................................................................... 5 2.A.3 Loads supported by grease lubricated journal bearing. ....................................................... 6 2.A.4 Wear/ losses prevailing in grease lubricated journal bearing: ............................................. 6 2.A.5 Mounting of journal bearing:............................................................................................... 7 2.A.6 Critical comments on the bearing selection criteria ............................................................ 7 2.B Construction machine equipment selection for bearing analysis: .......................................... 8 2.B.1 Introduction to hydraulic piston pump[3]: ........................................................................... 8 2.B.2 Bearing used in piston pump (construction machine equipment): ...................................... 9 2.B.3 Load carrying capacity of Taper roller bearing: .................................................................. 9 2.B.4 Lubrication for bearing used in piston pump ..................................................................... 10 iv

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2.B.5 Wear/ losses prevailing in taper roller bearing: ................................................................. 10 2.B.6 Mounting of taper roller bearing: ...................................................................................... 11 2.B.7 Critical comments on taper roller bearing selection: ......................................................... 12 2.C.0 Partial journal bearing calculation. .................................................................................... 13 2.C.1 Determining the sommerfield number from graph ............................................................ 13 2.C.2 Determining the diametrical clearance ratio: ..................................................................... 15 2.C.3 Determining the eccentricity ratio: .................................................................................... 15 2.C.4 Determining the Pressure(P): ............................................................................................. 17 2.C.5 Determining the maximum pressure (Pmax): .................................................................... 17 2.C.6 Determining the co efficient of friction: ............................................................................ 17 2.C.7 Determining the load carrying capacity (W): .................................................................... 17 2.C.8 Comments on the result obtained: ..................................................................................... 18 3.0 Determining the inlet for journal bearing: ............................................................................. 19 3.1 Determining the velocity (V): ............................................................................................... 20 3.2 Determining the diametrical clearance ratio: ........................................................................ 20 3.3 Determining the constant pressure: ....................................................................................... 20 3.4 Determining the pressure at different angles: ........................................................................ 21 3.5 Possible chances of leakage:.................................................................................................. 25 3.6 Comments on obtained result: ............................................................................................... 25 4.0 learning outcome: .................................................................................................................. 26 References ................................................................................................................................... 27

List of Tables
____________________________________________________________________________ Table No. Title of table Pg.No Table 1.1 Testing conditions of bearing Table 3.1 Comparison of pressure at different angle 01 02

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List of Figures
____________________________________________________________________________ Figure No. Title of figure Pg.No Fig 1.1 Comparing optimum condition and worst condition Fig 2.1 Wheel loader Fig 2.2 Showing grease lubricated journal bearing in loading unit Fig 2.3 Cross section of journal bearing with shaft assembly Fig 2.4 showing bearing with loads Fig 2.5 showing pressure &velocity graph Fig 2.6 Edge loading due to shaft misalignment Fig 2.7 Edge loading by misalignment & bending Fig 2.8 Showing hydraulic excavator using piston pump Fig 2.9 cross section of piston pump Fig 2.10 loads taken by taper roller bearing Fig 2.11 Influence of angle in taper roller bearing Fig 2.12 Bearing lubrication in piston pump Fig 2.13 Life reduction due to contaminants Fig 2.14&2.15 showing electric current wear Fig 2.16&2.17 showing brinelling wear Fig 2.18 showing bearing puller Fig 2.19 Minimum film thickness and sommer field number Fig 2.20 Selection of sommer field number Fig 2.21 Showing relation of(B/L) ratio and (Pmax/P) ratio & () curve Fig 2.22 Selection of pressure ratio Fig 2.23 showing the bearing is heavily loaded Fig 3.1 Oil film pressure distribution in the full journal bearing Fig 3.2 Pressure distribution in lubrication oil 04 05 05 06 06 07 07 08 09 09 09 10 10 11 11 12 14 14 16 16 18 19 25 01

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List of Symbols
____________________________________________________________________________

Symbol Pi Pr Po P P0i

Description Inlet Pressure Resultant Pressure Poissons Ratio Pressure at different Angles The New inlet Pressure Co-efficient of Friction Radial Clearance

Units N/m2 N/m2 N/m2 N/m2 N/m2

.
W e S P

mm degrees mm

Angle Min film thickness Diametrical Clearance ratio Load carrying capacity eccentricity Eccentricity Ratio Sommerfield number Pressure Maximum Pressure Minimum Pressure

N mm

N/m2 N/m2 N/m2

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PART-A CHAPTER 1

1.0Introduction
Bearing allow the relative movement between the machine components, such as provides free rotation of shafts and also provides some location between them. Generally bearings are classified into two types based on its contact area. i. Rolling contact In rolling contact load is transferred through rolling elements such as balls, straight and tapered cylinders and spherical rollers. ii. Journal bearings In Journal bearings load is transferred through a thin film of lubricant.

The application of bearing is very wide and used in all types of machines which is available in many verities of types, precision and sizes etc. This debate is about the selection of bearing depends only on the load carrying capacity of the bearing. Generally by considering only the load carrying capacity and selecting the bearing is not possible many other factors are also need to be considered.

1.1 The various factors to be considered in bearing selection:

Apart from the load carrying capacity the many other factors such as the external factors like environmental conditions, loads, directions, vibrations, noise, torque, rigidity, and lubrication life and so on is needed to be considered. And the bearing construction factors such as precision, cage structure and fit are need to be considered. As the bearings are very precision components and are expected to perform at high speeds, rotary accuracy and operated at high torque it is required to consider all these factors.

1.1.1 Environmental and operating condition (Areas of application):

This factor is required to considered in bearing selection involves which provides the information of operating conditions such as load on bearing, speed and mounting space, temperature, surrounding conditions, shaft arrangements and rigidity of mounting seats apart from this lubrication and maintenance of bearing and mounting and dismounting is needed to be analyzed to obtain the prolonged bearing life and effective usage of bearing.

1.1.2 Load carrying capacity:

Generally bearings are subjected to the following loads (i) Radial loads (ii) Axial loads and (iii) Combination of both. All bearing will not take all type of loads, all bearings are restricted to operating loads such as needle bearings can take only radial loads, cylindrical roller bearing can take very good Radial Loads but poor axial loads. So while selecting the bearing the load to which the bearing subjected to is needs to be considered.

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1.1.3 Considering the bearing dimension:

While selecting the bearing it is required to consider the bearing dimensions and select the bearing. Which in turn provides required design life, can able to withstand dynamic and static loads, can be operated at required speed.

1.1.4 Considering the precision of bearing:

While selecting bearing precision of bearing needs to be considered which provides running accuracy of rotating shaft at variation in torque and variation in speeds.

1.1.5 Considering the bearing clearance (Eccentricity):

The bearing clearance results in eccentricity in bearing which provides the space for lubrication to flow between the bearing and shaft to avoid friction wear and also provides heat transfer in bearings. The excessive clearance also results in reduction of bearing life so it is required to select the optimum clearance.

1.1.6 Considering the lubrication method:

Lubrication is the important aspect needs to be considered which acts as load carrying member. If lubrication is not properly done, metal to metal contact exists and results in friction and wear based on operating temperature from various type of lubrication methods like hydrostatic, hydrodynamic and sealed lubrication suitable one can be selected.

1.1.7 Installation and disassembly:

Some applications require frequent dismantling and assembling to enable periodic inspections and repairs for such applications the bearing with separatable inner and outer race of roller bearing can be used Incorporation of adapter sleeves simplifies the installation and disassembly of self aligning ball bearings and spherical roller bearings fixed to the taper bores.

1.2 Case study[1]:

In the following case study by Kazuaki Maniwa[1] on Optimal design of ball bearing using taguchi methods and bearing dynamic analysis for Japan Aerospace Exploration Agency (JAXA). The author has discussed about optimum design of ball bearing which includes dynamic consideration of bearings with lubrication along with the analysis of contact of ball with outer and inner race. This case study gives the clear idea about the various factors to be considered while selection of bearing. The oil lubricated ball bearing which runs at the high speed has wide application in space components, these bearings are also operated low frictional torque under the vacuum normal lubricant oil is not suitable for this operating condition were a special A cottonbased phenol retainer impregnated with the lubricant oil is used. During the operation the cotton

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based lubricant leads to frictional torque and results in heavy noise. According to the author these noise is caused by the clearance present in the cage. With this we can able to identify that the even the design of the cage is needed to be considered while selecting the bearing and also it is to be noted that the lubrication will also differed based on the application of the bearing so all these factors influences the selection of bearing. In the further analysis the bearing is tested into a specific environment to obtain the results for which the parameters are considered as shown in the Table 1.1.

Table1.1[1] Testing conditions of bearing Fig 1.1[1] comparing optimum condition and worst condition. Were the results of optimum condition and worst conditions in the bearings are analyzed as shown in the fig 1.1These test is been conducted at the various temperature and with different lubrication were different results were obtained. With this case study we can know that the performance of bearing depends not only on load carrying capacity but also on other several factors.

1.3 Conclusion:
The bearing performance is depends on the many factors not only on the load carrying capacity. As the efficiency of the bearings reduces, with the change in lubrication, temperature, clearance in bearing etc. And from the above case study we can note that even the clearance in the cage which comes under the bearing construction causes the noise. And also it should be noted that the lubrication for the bearing plays the important role in the bearing function so it is required to select the proper lubrication. Suppose if we consider two bearings one is of spherical roller bearing and other is of angular contact spherical bearing both of these bearings has same load carrying capacity if we notice the performance the angular contact spherical bearing will perform well as there is provision of self aligning any eccentricity in shaft is slightly compensated while rotation. With this we can know that load carrying capacity is not only the factor which is to be considered while selection of bearing.

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PART-B CHAPTER 2 ________________________________________________________________________________

Q1. Visit EXCON-2011 expo on construction and mining machinery being held at BIEC Bangalore. Based on the visit prepare report on the following lines: 1. Indentify any two types of construction / mining machinery 2. Types of bearings in selected machines 3. Role of bearings in the machines and bearing selection on basis of types of loads 4. Details of bearing mounting and kind of wear/ losses prevailing 5. Lubrication method
6. Critical comments on the bearing selection criteria and suggestions for

improvement if any. 2.A Introduction to grease lubricated journal bearing[2]:

Grease lubricated journal bearing are generally used in construction machine Volvo wheel loader as it is easy to replace when it is worn out, Simple design, Very less change to environmental impact and Increased efficiency. Bearings in construction machines are subjected to very high loads with less sliding speeds. The grease lubricated journal bearings are in use from the earliest civilization the same principle of rotating shaft in the lubricated hole is followed in this type of bearing also, But nowadays the rotating shaft is guided by means of the bush made of bronze, plastics etc. Today in the construction machineries the loads on the bearings are increased and the size of the bearings are reduced, in order to withstand this type of load the area of contact should be more since the journal bearing provides surface to surface contact can able to withstand heavy loads.

Fig 2.1 wheel loader

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2.A.1 Loading unit of wheel loader:

The loading unit is generally placed at the front portion of wheel loader a square wide bucket connected at the two ends with arms and supported by hydraulic cylinder. It is generally used to carry loose material from ground such as sand, wastes etc. The loader assembly can be easily detachable and attachable on wheel loader. The loading unit of wheel loader has many number of grease lubricated journal bearing as shown in the fig 2.2 below.

Fig 2.2[2] Showing grease lubricated journal bearing in loading unit

2.A.2 Lubrication methods:

Generally boundary lubrication system is carried out in this type of bearings by applying grease between the journal and the shaft. These bearings are subjected to very high and varying dynamic loads at various temperatures and various sliding speeds .Which results in insufficient lubrication the shaft and bearing will be in contact and wear takes place and often it is required to change the journal as well as the lubricant. The possible remedy to keep the grease within the journal until it is fully consumed is by providing seals for bearing as shown in the fig 2.3below.

Fig 2.3[2] Cross section of journal bearing with shaft assembly

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2.A.3 Loads supported by grease lubricated journal bearing.

Generally this type of bearings withstands high radial loads and is not suitable for axial loads. In general construction machines are subjected to very high loads together with low limiting speeds at various temperatures. The values of pressures lies between 100-200Mpa and sliding speeds are in the range of 0.01 to 0.1m/s. The surface pressure in the inner circumferential area of the bearing should be 50% hardness of the shaft to avoid seizing when subjected to heavy loads and to avoid wear in the shaft.

Fig 2.4[2] showing bearing with loads

Fig 2.5[2] showing pressure &velocity graph

The maximum limit of pressure (P) is related with the mechanical strength and the limit of sliding velocity (v) results in the frictional heating of materials. For a bearing material if it exceeds this pv value will not be able to absorb the friction energy thus seizing takes place. For journal bearing in construction equipments velocity limit is less and can be neglected and only pressure factor to be considered. The pressure velocity graph has shown in fig 2.4.

2.A.4 Wear/ losses prevailing in grease lubricated journal bearing:

As this type of bearing is grease lubricated it is essential to lubricate often with the grease. Since the construction machines are operated at harsh conditions the dynamic loads tries to remove the lubricant from the bearing which leads to surface to surface contact results in wear. The machine used for very hard replenishment should be applied with the grease daily. And if the bush of the bearing is short will result in edge loading will takes place due to shaft misalignment as shown in the fig 2.5 this edge loading can be avoided by providing lengthier bush. But the lengthier bush has problem with bending, deflection takes place as shown in fig 2.6 to overcome this the diametrical ratio (w/d) has to be maintained to the ratio of 1:3.

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Fig 2.6[2] Edge loading due to shaft misalignment Fig 2.7[2] Edge loading by misalignment & bending

2.A.5 Mounting of journal bearing:

Bearing mounting plays an important role in bearing life cycle. If the bearing is not mounted properly using the correct tools and methods the bearing life gets reduced. According to SKF bearing manufacturers [1] Around 16% of all premature bearing failures are a result of poor fitting or using incorrect mounting techniques the journal bearings are generally mounted using the following methods. 1. Cold mounting It is the general method of mounting a bearing by using a hallow pipe and placing it on the baring bush and above the hallow pipe wood is placed and by gently hammering on the wood bearing is mounted. 2. Temperature mounting Temperature mounting is the method of obtaining an interference fit by first introducing a temperature differential between the parts to be fitted, thereby making the assembly easier. The temperature differential method is suitable for any bearing size, Because of the equipment required, the cold mounting method is used wherever possible for bearings under a 10.16cm outside diameter. 3. Hydraulic mounting It is based on forcing oil between the interfering surfaces, thereby greatly reducing the required axial force. The pressure is generally supplied with a manually operated pump with a maximum pressure of 10,000 psi.

2.A.6 Critical comments on the bearing selection criteria

As in ball bearing only the point contact exists and in roller bearings line contact exists but in journal bearing surface contact exists which ensures high radial load carrying capacity. As the diameter of shaft is large and cost of the bearing is cheaper than the other type and easy

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maintenance is possible in journal bearing, quite operation with low noise is the important points which are been considered for bearing selection. The main drawback for this grease lubricated bearing is lubrication were grease is used for the lubrication of the bearing which is applied manually if in case if proper scheduling of lubrication is not done will be resulting in the bearing wear. As the bearing is fully protected from the environmental conditions will protect the contamination the lubrication. As the machine is subjected to very high dynamic loads the increased area of contact in the bearing supports the high performance of the machine.

2.B Construction machine equipment selection for bearing analysis: 2.B.1 Introduction to hydraulic piston pump[3]:

Fig 2.8 Showing hydraulic excavator using piston pump. Piston pumps are used in all types of construction machines such as wheel loader, hydraulic excavator, crewel dozer etc. Piston pumps are generally used in construction machines for actuating the telescopic cylinders which is fixed to the arm and the shovel of the construction machines. The piston construction is of many number of pistons are arranged in a circular array inside the cylindrical block or barrel, the cylindrical barrel is tilted to a certain angle in the housing. The output shaft has grooves for location of pistons. Pressure will be developed by movement of pistons on the output shaft when the output shaft is rotated by driving unit. The angle tilted in barrel creates reduction in volume which helps to build up the pressure in the oil. These pumps are used to build up pressure up to 200 bars.

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Fig 2.9[3] cross section of piston pump

2.B.2 Bearing used in piston pump (construction machine equipment):

The bearing used in the piston pump is taper roller bearing. As to generate the high pressure in the pump the output/input shaft has to be rotated at high Rpm. Since the taper roller bearing is suitable for radial and axial loads it is used in piston pump. The shaft rotates at the high rpm and due to torque axial load will be acting and similarly due to the difference in pressure of the fluid and due to centrifugal force the radial load will also act on the bearing to withstand these combinations of two loads taper roller bearing is used in piston pump.

2.B.3 Load carrying capacity of Taper roller bearing:

Taper roller bearing has tapered inner and outer race between these races taper roller. The projection line of all tapered surface meets at the common point on the bearing axis which helps the taper roller bearing to withstand combined loads. The axial load carrying capacity of these bearings depends on the contact angle. The larger the contact angle, the higher the axial load carrying capacity. As mostly the input /output shaft used in piston pump is subjected to combination loads these taper roller bearing is most suitable the other advantage is even in the contaminated oil it gives high life are the factors behind the taper roller bearing selection.

Fig 2.10 loads taken by taper roller bearing

Fig 2.11 Influence of angle in taper roller bearing

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The fig 2.10 shows the influence of angle in taper roller bearing in which (A) is for light loads as the angle is less (B) is for moderate loads (C) the angle is more the load carrying capacity is high.

2.B.4 Lubrication for bearing used in piston pump

As the taper roller bearing in the assembly it is placed inside the barrel were the barrel is always filled with the hydraulic oil so the taper roller bearing will be immersed inside the oil whenever the pump is functioning so there is no need for separate lubrication as the bearing lubrication is provided by the hydraulic oil itself while passing through the barrel as shown in the fig 2.12 And fig 2.13 shows life reduction of bearing due to contaminants.

Fig 2.12[3] Bearing lubrication in piston pump Fig 2.13[5] Life reduction due to contaminants

2.B.5 Wear/ losses prevailing in taper roller bearing:

Commonly the wear/loss in taper roller bearing occurs due to insufficient maintenance practice, mishandling, improper installation and adjustment practices. The common type of wear caused to the bearing in the piston pump are (i) Electric current wear which is shown in fig 2.14 &2.15 which is caused due to the supply of electric current to bearing. Which is caused by improper power supply and improper earthing etc.

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Fig 2.14[7] &Fig2.15 [7] showing electric current wear The other type of possible wear can occurs in taper roller bearing present in piston pump is brinelling which is of two types (i) True brinelling and (ii) False brinelling. Were true brinelling is caused by shock and impact loads and false brinelling is caused by vibrations or relative axial movement between rollers and races as shown in the fig 2.16 & 2.17 below

Fig 2.16[7] &Fig2.17[7] showing brinelling wear

2.B.6 Mounting of taper roller bearing:

Taper roller bearing can be mounted by means of the special equipment using bearing puller/mounter as shown in the fig 2.18 below. Which has four arms which is connected to central threaded screw by rotating these screw the arm gets opened and closed equally, The arms should be opened to size of the inner diameter of inner race until it gets clamped rigidly and gently by placing the bearing in the bore and by hitting gently on the bearing puller bearing is fixed in the bore.

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Fig 2.18[6] showing bearing puller

2.B.7 Critical comments on taper roller bearing selection:

As taper roller bearing is suitable for radial and combination of radial and axial loads in piston pump is subjected to combination loads. The axial loads is from shaft as the shaft is rotating at the high Rpm torque is generated axially and due to the centrifugal force generated in fluids due to the rotation of pistons the bearing will also subjected to radial forces for these combined loads only the taper roller bearing is the proper selection. Apart from this the bearing is immersed in the hydraulic oil any contaminants in the oil results in damaging the bearing as the taper roller bearing will function effectively even the oil is contaminated so taper roller bearing is selected in piston pump. While compared taper roller bearing with spherical roller bearing in spherical roller bearing point contact exist but in taper roller bearing line contact exists so the taper roller bearing can withstand very high loads.

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2.C.0 Partial journal bearing calculation. A partial journal bearing (120 deg loading) has the following specifications Diameter D , length of the bearing L, Speed N, Viscosity of the lubricant = 0.04 Pas. Assuming a clearance of 1.4 mm of diameter, calculate the following using graphs. 1. Load carrying capacity of the bearing corresponding to minimum oil film thickness of 0.00620mm. 2. Coefficient of friction 3. Maximum pressure in the oil
Given data: Diameter (D) = 60mm = 60 x 10-3 m. Length (L) = 200mm = 200 x 10-3 m. Number of revolution (N) = 4000 Rpm. = 0.04 pas Diametrical clearance (C) = 1.40 x 10-3m. Hmin = 0.00620mm = 0.00620 x 10-3m. Solution:

2.C.1 Determining the sommerfield number from graph

From the Fig 24.11 by comparing minimum film thickness and sommerfield with partial journal bearing loading () = 120 we get, Sommerfield number (S) = 0.02

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Fig 2.19 Minimum film thickness and sommer field number

Fig 2.20[8] Selection of sommer field number

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N = N/60 = 4000/60 = 66.66Rps.

2.C.2 Determining the diametrical clearance ratio:

[DHB 24-29]

= 0.02 ( ) ( B = 62.83 x 10-3 m. ( ) ) [FROM SLIDE]

2.C.3 Determining the eccentricity ratio:

To find eccentricity ratio () By applying: e = C- Hmin e = 1.40 x 10-3 0.00620 x 10-3 e = 1.393 x 10-3m. By substituting (e) in () [Ses-6, Slide-40]

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= 0.995

From the fig 24-27 of the graph which show relation between pressure ratio and (B/L) ratio with respect to eccentricity ratio curve () w get (Pmax/P) = 4.20.

Fig 2.21[8] showing relation of(B/L) ratio and (Pmax/P) ratio & () curve

Fig 2.22[8] Selection of pressure ratio

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2.C.4 Determining the Pressure(P):

To find (P) using sommerfield number (S) [DHB 24-39]

P = 330000kgf/m2

2.C.5 Determining the maximum pressure (Pmax):

By substituting P = 330000kgf/m2 in the formula we get

2.C.6 Determining the co efficient of friction:

To find the co efficient of friction ( ) by applying the formula ( )( ) [DHB24-21]

)(

= 7.97 x 10-3m

2.C.7 Determining the load carrying capacity (W):

The load carrying capacity of the bearing can be determined by ( U = DN U= x 1.40 x 10-3 x 66.66 ) [DHB 24-38]

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U= 12.56m/s.

( ( W = 12.668kg. )

2.C.8 Comments on the result obtained:

For the given partial journal bearing 120 loading condition, from graph we get the sommer field number as 0.02 the load carrying capacity is as 12.668kg. co efficient of friction ()= 7.97x10-3m. The maximum pressure in the oil is (Pmax) = 1254000kgf/m2and also we can notice that from the Fig the bearing is heavily loaded as the sommer field number value is 0.02 which is less than 0.15.

Fig 2.23[8] Fig showing the bearing is heavily loaded

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PART-C CHAPTER 3 ________________________________________________________________________________

3.0 Determining the inlet for journal bearing: Q3. The configuration of journal bearing is, Diameter of the journal =4cm, length of the bearing=6cm, maximum speed of rotation of journal bearing =N rpm, radial clearance between axle and bearing=2.0x10 cm, oil supply pressure at inlet of the bearing= P [MPa], location of oil inlet hole= [degrees], Attitude of bearing=0.8. The lubricant having viscosity of 0.0148N-s/m2 As a tribologist, how do you avoid leakage problem? It should be noted that where ever the pressure in oil film is negative, bearing tends to leak.
Given data: Diameter (D) = 4cm = 4x10-2m. Length (L) = 6cm= 6x10-2m. N = 600Rpm N = 10 Rps Cr = 2x10-3 cm = 2x10-5m. P = 0.6Mpa = 0.6x10-6m = 60 N-s/m2 Solution:
-3

Fig 3.1[8] Oil film pressure distribution in the full journal bearing

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Pressure distribution on journal bearing can be determined by the formula. ( ( )( )

3.1 Determining the velocity (V):

To determine the velocity U U = DN U = x 4x10-2 x 10 U = 1.25m/s. [DHB 24-18]

3.2 Determining the diametrical clearance ratio:

To find the diametrical clearance ratio (). [DHB 24-29]

=1x10-3

3.3 Determining the constant pressure:

To determine the constant pressure in the journal bearing when = 0. [DHB24-36]

P0 = - 4.9 x 106

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To determine the inlet were leakage will not takes place, Pressure at different angles (inlet position) needs to be calculated. The formula to calculate pressure in journal bearing is ( ( )( ) [DHB 24-36]

3.4 Determining the pressure at different angles:

Substituting the value of =0 in the formula we get. ( ( P = 0Pa Substituting the value of =30 in the formula we get. ( ( ) ( )( ) ) ) ( )( ) )

( P = 1.31x106 Pa Substituting the value of =60 in the formula we get. ( ( ) (

)(

) )( )

P = 2.29x106 Pa

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Substituting the value of

=90 in the formula we get. ( ( ) ( )( ) )

P = 3.3x106 Pa Substituting the value of =120 in the formula we get. ( ( ) ( )( ) )

P = 3.82x106Pa Substituting the value of =150 in the formula we get. ( ( ) ( )( ) )

P = 3.53x106 Pa Substituting the value of =180 in the formula we get. ( ( ) ( )( ) )

P = 0Pa

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Substituting the value of

=210 in the formula we get. ( ( ) ( )( ) )

P = -3.53x106 Pa Substituting the value of =240 in the formula we get. ( ( ) ( )( ) )

P = -3.82x106Pa Substituting the value of =270 in the formula we get. ( ( ) ( )( ) )

P = -3.3x106 Pa Substituting the value of =300 in the formula we get. ( ( ) ( )( ) )

P = -2.29 x106Pa

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MSRSAS - Postgraduate Engineering and Management Programme - PEMP

Substituting the value of

=330 in the formula we get. ( ( ) ( )( ) )

P = -1.31x106 Pa

In the Table3.1 The comparison of pressure in the lubrication oil at the different angle is shown to verify that the current inlet position is suitable position or if there is possibilities of negative pressure the position angle is to be changed.

A B

0 0

30 1.31 x10
6

60 2.29 x10
6

90 3.3 x10
6

120 3.82 x10

6

150 3.53 x10

6

180 0

210 -3.53 x10

6

240 -3.82 x10

6

270 -3.3 x10

6

300 -2.29 x10

6

330 -1.31 x106

Table 3.1 Comparison of pressure at different angle A= position of inlet in various angle in degrees B=Pressure at various angles in Pascal

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MSRSAS - Postgraduate Engineering and Management Programme - PEMP

In the Fig 3.1 showing the pressure distribution in the lubrication oil at the various angle which gives the clear idea about the condition of inlet position and the pressure at the inlet position.

Fig 3.2 pressure distribution in lubrication oil

3.5 Possible chances of leakage:

When the pressure value is negative there is the chances of causing the leakage such angle should not be selected for inlet. The area at which turbulent flow or reversible flow exist such area should not be selected for Inlet. When the velocity of the fluid is high such area should not be selected for Inlet.

3.6 Comments on obtained result:

The current inlet position is at 60 were the existing pressure in the lubrication oil is 2.29 which has positive value the pressure is also comparatively less so there in the fluid exists high velocity and also laminar flow takes place. Since the velocity is high and pressure is low in the lubrication oil there is no possibility of vacuum generation and to take reversible flow. So inlet valve need not to be change. In the current position of the inlet valve leakage will not occur.

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4.0 learning outcome:

In the module Tribology and heat transfer the various concepts of Tribology like friction, wear and lubrication were covered. The important factor which is to be noted is the friction and wear based on the application it differs in some areas wear is required to accomplish its function and in some areas friction is required to accomplish its function such as in brake shoes etc. The concept of the lubrication and various types of lubrication and the effect of viscosity with temperature and pressure and how to select the lubrication was explained. The concepts of bearing and its types hydrostatic bearing and hydrodynamic bearings and their functions and applications, selection of bearings was explained. In the problem session the various problems was solved like determining the life of bearing, determining coefficient of friction, torque on bearings and hydrostatic, hydrodynamic and partial journal bearing was solved. The concept of usage of design data hand book and referring the various graphs for the calculation was explained. In the lab session an Introduction to hyper mesh software to create and do meshing of 2D geometry was learned. The usage of Gambit software to create mesh file and by using Fluent software analyzing the various 2D geometry of pressure, velocity, temperature, fluid path line analysis in the bearing was learned in the lab session.

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References
________________________________________________________________________________ 1. Kazuaki Maniwa, Optimal design of ball bearing using taguchi methods and bearing dynamic analysis for Japan Aerospace Exploration Agency (JAXA).

http://www.esmats.eu/esmatspapers/pastpapers/pdfs/2011/maniwa.pdf Retrieved on 28 12 2011. 2. Henriks strand, Design testing analysis of journal bearing in construction machines http:// kth.diva-portal.org/smash/get/diva2:11656/FULLTEXT01 retrieved on 28 12 2011. 3. Unknown, hydraulic motor pumpseries http:// www.parker.com/ .../hydraulicpump/cat/... /F11-F12 Retrieved on 22 12 2011. 4. Unknown,bearing failure and their causes www.skf.com/files/259501.pdf Retrieved on 3012 2011. 5. Unknown rolling bearing lubrication http://mountingmanager.schaeffler.com/.../library.pdf.wl81.115.e.pdf. Retrieved on 30 12 2011. 6. Unknown, Multi-row tapered roller bearings - FAG http:// www.fag.de/...fag...4/...row_tapered_roller_bearings/multi-row_taper Retrieved on 31 12 2011 7. Unknown, Tapered Roller Bearing Damage Analysis http://www.timken.com/en-us/products/maintdiag/Documents/6347.pdf Retrieved on 30 12 2011. 8. Lingaiah. K, machine design data hand book Tata McGraw hills publication 6th Edition.

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