BITS Pilani

Pilani Campus

VINAYAK KALLURI

BITS Pilani
Pilani Campus

Introduction
Objective of lubrication is to reduce friction, wear and heating of machine parts which move relative to each other. Lubricant is exactly that substance which does the above when inserted between moving surfaces. Lubrication is needed everywhere, for example, sleeve bearings, antifriction bearing, cam and follower, gear teeth, piston in cylinder, crank shaft and connecting rod bearings.
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Introduction
In a sleeve bearing, a shaft, or journal, rotates or oscillates within a sleeve, or bushing, and the relative motion is sliding. Frequently used in high load, high speed or high precision applications where ordinary ball bearings have short life or high noise and vibration. In applications requiring low load bearing capacity, nylon bearings requiring no lubrication, a powder metallurgy bearing with lubricant built-in, a bronze bearing with ring oiling, solid lubricant film or grease lubrication may be satisfactory
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CLASSIFICATION
Bearings are classified in two ways. 1. Based on type of load carried
a. Radial bearings b. Thrust bearings or axial bearings c. Radial thrust bearings

2. Based on lubrication mechanism

a. Hydrodynamic lubricated bearings b. Hydrostatic lubricated bearings c. Elastohydrodynamic lubricated bearings d. Boundary lubricated bearings e. Solid film lubricated bearings
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Radial bearings

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Thrust bearings / axial bearings / Collar bearings

Single collar thrust bearing

Multiple collar thrust bearing

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Radial thrust bearings

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Types of Lubrication 1. 2. 3. 4. 5. Hydrodynamic Hydrostatic Elastohydrodynamic Boundary Solid film

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Hydrodynamic (full-film) Lubrication

Metal-to-metal contact is prevented by a thick film of lubricant present in between the bearing surfaces. The film pressure is created by the moving surface itself by pulling the lubricant into a wedge-shaped zone at a velocity sufficiently high to create the pressure necessary to separate the surfaces against the load on the bearing Stability can be explained by the laws of fluid mechanics.

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Hydrostatic Lubrication

Lubricant is introduced into the load-bearing area at a pressure high enough to separate the surfaces with a relatively thick film of lubricant. Lubrication does not require motion of one surface relative to another. Considered in designing where the velocities are small or the frictional resistance is to be an absolute minimum.

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Elastohydrodynamic Lubrication
Lubricant is introduced between surfaces that are in rolling contact, such as mating gears, rolling bearings and cams etc. The mathematical explanation requires the Hertzian theory of contact stress and fluid mechanics.

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Boundary lubrication
Insufficient surface area, drop in velocity, lessening of lubricant quantity, increase in bearing load, or increase in lubricant temperature lead to a decrease in viscosityany one of thesemay prevent the buildup of a film thick enough for full-film lubrication. Bearings operating in above situations are called boundary lubricated bearings. Mixed hydrodynamic- and boundary-type lubrication occurs first, and as the surfaces move closer together, the boundary-type lubrication becomes predominant. Fluid mechanics and viscosity are less important and chemical composition is more important
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Solid-film Lubrication
Necessary when operation is to be at extremely high temperatures because ordinary minerals oils degrade; Graphite and Molybdenum disulphide are often used Composite bearing materials are being researched because liquid lubricants also proved to be environmentally non-sustainable

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Viscosity

Imagine the film as composed of a series of horizontal layers and the force F causing these layers to deform or slide on one another just like a deck of cards Intermediate layers have velocities that depend upon their distances y from the stationary surface
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Saybolt universal viscosimeter of ASTM

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Viscosity from Saybolt viscosimeter

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Figure 122: A comparison of the viscosities of various fluids.

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PETROFFS EQUATION:

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PETROFFS EQUATION:

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Stable Lubrication
McKee brothers explained the difference between boundary (unstable) and hydrodynamic (stable) lubrication in an actual test of friction by reference to Fig. Region to the right of line AB defines stable lubrication because variations are self-correcting. Region to the left of line AB represents unstable lubrication. Point C represents what is probably the beginning of metal-to-metal contact as N/P becomes smaller.

Design Constraint:

N
P

1 . 7 10

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Thick Film Lubrication

An eccentricity ratio,

e c

h0 h0 = c e =1 c
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Design Considerations
Values either given or are under the control of the designer are 1. The viscosity 2. The load per unit of projected bearing area, P 3. The speed N 4. The bearing dimensions r, c, , and l The dependent variables (designer cannot control these except indirectly by changing one or more of the above group) are 1. The coefficient of friction f 2. The temperature rise T 3. The volume flow rate of oil Q 4. The minimum film thickness h0
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Significant Angular Speed

It has been discovered that the angular speed N that is significant to hydrodynamic film bearing performance is

Fig. 12.11
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The Relations of the Variables

Albert A. Raimondi and John Boyd, of Westinghouse Research Laboratories, used an iteration technique to solve Reynolds equation on the digital computer charts are used to define the variables for length-diameter (l/d) ratios of 1:4, 1:2, and 1 and for beta angles of 60 to 360. The charts appearing in text book are for full journal bearings ( = 360) only. For other categories, refer
A. A. Raimondi and John Boyd, A Solution for the Finite Journal Bearing and Its Application to Analysis and Design, Parts I, II, and III, Trans. ASLE, vol. 1, no. 1, in Lubrication Science and Technology, Pergamon, New York, 1958, pp. 159209.
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Viscosity Charts: I
Fig. 12.12

viscosity used in the analysis must correspond to Tav.

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Viscosity Charts: II

Fig. 12.13

viscosity used in the analysis must correspond to Tav.

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The remaining charts from Raimondi and Boyd relate several variables to the Somerfield number. These variables are
Minimum film thickness Coefficient of friction Lubricant flow Film pressure

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Filmpressure distribution notation

W = bearing load (N) N = speed (rps) h0 = minimum film-thickness (mm) e = eccentricity (mm) P = film pressure (MPa) Pmax= max fill pressure (MPa) = position of the minimum film thickness po = terminating position of the lubricant film pmax = the position of maximum film pressure.

Fig. 12.15
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Chart for minimum film-thickness variable and eccentricity ratio.

Fig. 12.16

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Chart for the position of the minimum film thickness

Fig. 12.17

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Chart for coefficient-of-friction variable;

Fig. 12.18

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Chart for flow variable

Fig. 12.19

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Chart for determining the ratio of side flow to total flow.

Fig. 12.20
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Chart for determining the maximum film pressure.

Fig. 12.21

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Chart for the terminating position of the lubricant film and the position of maximum film pressure.

Fig. 12.22

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Problem:
A full journal bearing has a journal diameter of 40 mm, with a unilateral tolerance of 0.025 mm. The bushing bore has a diameter of 40.08 mm and a unilateral tolerance of 0.075 mm. The bearing is 40 mm long. The journal load is 2.2 kN and it runs at a speed of 1800 rev/min. Using an average viscosity of 25 mPa.s, find the minimum film thickness, eccentricity, position of minimum film thickness, coefficient of friction, the torque to overcome the friction, the power loss to friction, total volumetric flow rate of lubricant, side flow rate of lubricant, the maximum film pressure, and the location of maximum and terminating pressures, for the minimum clearance assembly.

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BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus

Problem
The rotating solid shaft shown in Figure, is simply supported by two full journal bearings at points B and C and is driven by a gear (not shown) which meshes with the spur gear at D. The spur gear at D has a 120-mm pitch diameter and a pressure angle of 25. The shaft transmits a steady torque of 500 N-m at 600 rpm. The shaft is made of steel with endurance strength (Se) of 200 MPa and tensile strength (Sut) of 540 MPa. If shaft is of uniform cross section, find the minimum allowable standard diameter of the shaft based on DE-Goodman fatigue-failure theory with factor of safety 2. It is decided to use a full journal bearing of length 50 mm at C. The shaft journal has a unilateral tolerance of 0.012 mm. The diameter of the bushing bore is 0.02 mm more than that of the shaft diameter and has a unilateral tolerance of +0.012 mm. For the minimum clearance assembly, find the minimum oil-film thickness, the power loss, and the lubricant side flow if the average operating temperature is 500C assuming SAE 20 lubricating oil is used.

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BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus