A Process Analysis Of Air Cooled Steel Ball Bearings

May 28, 2014, Davis, California, USA

Version Number 1.1

THE OPTIMIZATION OF COOLING PROCESSES FOR BALL BEARINGS
ABSTRACT
The objective of this design project is to efficiently cool steel
ball bearings as they are transported across a conveyor belt
system in a chilled dry air chamber. To ensure thorough and
sufficient cooling, various industrial air blowers were compared
with respect to their volumetric flow rate (in cubic feet per
minute, CFM) to yield the proper cooling rate and desired final
temperature. It was determined through simulation trials that
the TFD Flange Mount BC Airfoil Blower, model number
TFD280, would meet the manufacturing constraints outlined in
the request for proposal.

PROBLEM STATEMENT
The steel ball bearings enter a dry air chamber at an initial
temperature of 500C and are to be cooled to a temperature of
at least 150C prior to packaging. The conveyor belt transports
the ball bearings across a length of 20m in the air chamber,
where the dry air and surroundings are both held at a constant
temperature of -23C. In addition, the minimum conveyor belt
velocity is 0.1m/s, but can be varied to meet production
demands.

To adequately cool the ball bearings, an industrial air blower,
coupled with an air duct, generates the forced convection
around the bearings. In an effort to maintain the overall quality
and even cooling, the cooling rate of the ball bearings must not
exceed 6C/s.

As a simplification, heat transfer only in the forms of
convection and radiation are considered, as the effects of
conduction are negligible.
SOLUTION APPROACH
To begin sizing the proper air blower for the cooling
application, various air ducts were modeled to obtain a range of
cross-sectional areas that varied from 2ft
2
to 0.167ft
2
, as seen in
Table 2.1. This variation would allow the air velocity within the
chamber to be determined by Equation 1.1. For each particular
duct model, the air velocity was determined for standardized
volumetric flow rates ranging from approximately 400CFM to
4500CFM, as seen in Tables 2.1.

Following the aforementioned process, the Reynolds Number
(Equation 1.2) and Nusselt Number (Equation 1.3) were
determined for each duct model across the same volumetric
flow rate range (450CFM to 4500CFM). This would yield the
proper control variables that would be used to determine the
convective heat transfer coefficient, h, Equation 1.4.

With a data set of convective heat transfer coefficients ranging
from 15 to 250W/m
2
K, the cooling process was simulated using
numerical analysis software. In these simulations, the heat
transfer due to radiation was initially considered negligible to
obtain an approximate convective heat transfer coefficient that
would yield a final ball bearing temperature of less than 150C.
Once this experimental convective heat transfer coefficient was
determined, the other parameters, such as the ideal volumetric
flow rate and necessary air velocity, were recorded for
comparison to the actual blower attributes.

To determine the best fit air blower, the ideal volumetric flow
rate was compared to the actual flow rates of various air
blowers. In deciding the proper air blower, the similarity
between the two volumetric flow rates, in CFM, was the
primary factor, followed by the amount of static pressure at the
specified operating parameters. The ideal air blower would
provide a CFM that would be in between the allowable static
pressure range specified by the manufacturer, to allow for safe
flow rate changes if needed in the future.
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Steven Biasca
University of California, Davis
Figure 1: The TFD Flange Mount BC Airfoil Blower: TFD280 offers a
wide range of volumetric flow rates while also being capable of running at
two different RMP settings (1750 and 3450 RPMs).
RESULTS
From the numerical simulation, it was concluded that the
necessary air velocity and convective heat transfer coefficient
was 39.0m/s and 129.0W/m
2
K, respectively. The only air duct
configurations that yield these results all had cross-sectional
areas between 0.167ft
2
and 0.500ft
2
.

For this particular application, it was determined that an air
duct with a cross-sectional area of 0.250ft
2
would be the ideal
configuration. This would allow the duct to be connected to the
outlet of the air blower with a minor adapter connection, as
seen in Figure 2. To meet common industry sizing, the air duct
would utilize dimensions of 3in by 12in for the height and
width respectively. The air duct would be ported every 3ft with
similar dimensions for each outlet, 3in by 12in, to maintain a
constant cross-sectional area throughout the entire air duct
while distributing and directing the dry air across the ball
bearings on the conveyor belt.
With the duct designed to the prior dimensions, the industrial
air blower that most similarly fits the experimental data
obtained from the numerical simulation would be the TFD
Flange Mount BC Airfoil Blower: TFD280. The operating
parameters for this air blower in this cooling application would
be as follows:

-RPM Performance: 3450 RPMs
-Static Pressure: 2 in
-Volumetric Flow Rate: 2000 CFM
-Outlet Dimensions: 7.5 in by 10.1 in (height by width)

For the TFD280 running at these operating settings, it was
determined that the actual parameters were as follows:

-Air Flow Velocity: 40.640 m/s
-Reynolds Number: 142099.630
-Nusselt Number: 236.151
-Convection Coefficient, h: 131.654 W/m
2
K
-Biot Number: 0.01755 (note that lumped capacitance is valid)
From this it can be concluded that these parameters would yield
a ball bearing final temperature below the threshold
temperature of 150C. Upon simulation, the final temperature
neglecting the effects of radiation was approximately
146.749C, while the final temperature considering the effects
of radiation was approximately 144.458C, as seen in Figure 3.

Additional features of the TFD280 that make this an ideal air
blower for this application are the overall weight and
performance factors. According to Continental Fan
Manufacturing Inc., TFD Blowers feature TEK backward
curved airfoil impellers, the industry's quietest and most
efficient OEM impellers combined with modern high
strength plastics to produce a wheel that is stronger than steel,
yet half its weight. This was a major factor considering the air
blower would be mounted above the air duct. Suspending an air
blower that is significantly heavier and louder would create
both an installation issue as well as operational issues with
sound in the workplace. Furthermore, the TFD280 can also be
set to run at 1750 RPMs, which would allow for a wider range
of volumetric flow rates should they be needed for different
cooling applications on the same conveyor system in the future.

To ensure the quality of the
final product post-cooling,
the cooling rate with
respect to the bearings
location on the belt was
approximated for cases
including and neglecting
the effects of radiation,
Figure 4. For each case,
the cooling rate does not
exceed approxi mat el y
- 3 C / s , w h i c h i s
significantly lower than the
ma x i mu m a l l o wa b l e
cooling rate of -6C/s.
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0 2 4 6 8 10 12 14 16 18 20
100
150
200
250
300
350
400
450
500
Temperature of Ball Bearing, Convection
Length of conveyor belt (m)
T
e
m
p
e
r
a
tu
r
e
(
C
)
0 2 4 6 8 10 12 14 16 18 20
100
150
200
250
300
350
400
450
500
Temperature of Ball Bearing, Convection & Radiation
Length of conveyor belt (m)
Figure 3: The change in temperature relative to the ball bearings location on the
conveyor belt in both cases (with and without radiation effects) are very similar
to each other. However the heat transfer due to radiation allows a slightly lower
final temperature to be achieved when it is considered.
Figure 2: The air blower outlet would be mounted on the upper portion of the
air duct as seen above. The forced dry air would then be distributed to 21
different exhaust ports, equally spaced 3ft apart form each other, to evenly
subject the conveyor belt to the cooling air.
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Figure 4: Since the heat transfer due
to radiation is rather nominal,
considering radiation in the cooling
rate will only slightly increases the
rate of heat transfer.
DISCUSSION
During the process analysis for the ideal design, it becomes
evident that a significant amount of the heat transfer from the
ball bearings occurs through convection, when compared to
radiation. In both the experimental and actual simulations, the
addition of heat transfer through the form of radiation only
lowers the bearings final temperature by a nominal amount (by
2.350C and 2.291C for the experimental and actual cases,
respectively). However, this notion can be utilized in the design
selection process. Considering the limiting values for the
convective heat transfer coefficient were determined by using
heat transfer through only conduction, the chosen design
parameters may overcompensate (though by a minimal amount)
since the additional effects of radiation are ignored. Therefore,
if we consider the effects of radiation initially, then the required
air flow velocity, and thus the required CFM, could be lowered,
saving both energy and equipment costs -since blowers of a
high CFM capacity tend to cost more and require more energy
at higher operating rates. However, by ignoring this factor
upfront in the design process, we do create a safety buffer that
ensures the final product will be below the limiting temperature
of 150C.

It is also imperative to note that the simulation of the heat
transfer from the ball bearings goes beyond the delineated
limits that govern the calculation of the Nusselt Number. In
order for the Nusselt Number to be considered accurate and
ideal, the Reynolds Number used must be in the range of 3.5 to
7.6x10
4
. However, in order to achieve a convective heat
transfer coefficient that sufficiently contributes to the overall
cooling of the ball bearings, the air flow velocity must be high
enough such that the Reynolds Number is large enough to
increase the Nusselt Number, even if it is out of the governed
range. For the air blower selection and air duct design process,
we assume that this will not significantly discredit our
simulated results.

Furthermore, this design considers only cases in which the
velocity of the conveyor belt is held at a constant 0.1m/s.
Although it is desirable to increase this parameter for the sake
of production, the drawbacks in doing so significantly outweigh
the benefits. By simply doubling the conveyor belt speed to
0.2m/s as a test, the required minimum convective heat
coefficient spikes to 260W/m
2
K. Although not impossible to
obtain, such a high convective heat coefficient would call for an
air flow velocity of over 130.0m/s and a volumetric flow rate of
more than 4300CFM if coupled with an air duct with cross-
sectional area of 0.167ft
2
. Not only is this air flow velocity
significantly high (especially considering the products being
cooled are of minute size), but the duct dimensions required for
this flow are significantly small. Forcing such a high velocity
fluid through such a constrained duct would require that the
walls to be significantly reinforced to mitigate the chance of
ruptures. In addition, the cooling rate for such a case increases
to a maximum of approximately -4.394C/s, which becomes
closer to the maximum acceptable cooling rate, as seen in
Figure 5.

By employing a design that utilizes the TFD Flange Mount BC
Airfoil Blower: TFD280, the desired final temperature for the
ball bearings can be achieved with a reasonable air flow
velocity and volumetric flow rate. When matched with the
proper air duct, a safe cooling rate can be achieved that
guarantees the overall quality of the final product.
REFERENCES
Incopera, F. P. (2001). Fundamentals of Heat and Mass
Transfer. Chichester, New York: Wiley.

TFD Flange Mount BC Airfoil Blowers. Continental Fan
Manufacturing Inc., 2014. Web. 28 May 2014.


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Figure 5: By increasing the velocity of the conveyor belt, the cooling rate
that the ball bearing experiences also increases. This cooling rate, with a
maximum of -4.934C/s initially, considers the effects of both convection and
radiation.
APPENDIX A
1. RELEVANT EQUATIONS FOR DATA ANALYSIS

1.1. Air Velocity:

1.1.1. Volumetric Flow Rate: CFM (cubic feet per minute)
1.1.2. Cross-sectional Area of Duct:

1.2. Reynolds Number:

1.2.1. Ball Bearing Diameter: D
1.2.2. Kinematic Viscosity:

1.3. Nusselt Number:

1.3.1. Prandtl Number: Pr
1.3.2. Viscosity (at Tinf):
1.3.3. Viscosity (at Ts):

*We assume Ts is the average between the initial temperature (500C) and the desired final temperature
(150C). So Ts is evaluated at 325C (approximately 600K).

1.4. Convective Heat Transfer Coefficient:

1.4.1. Thermal Conductivity of Steel: k
1.4.2. Ball Bearing Diameter: D

2. EQUATIONS FOR HEAT FLUX DUE TO RADIATION

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2.1 Duct Characteristics
Length, ft 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000
Width, ft 2 1.5 1.25 1.0 0.75 0.5 0.25 0.167
Duct Area, ft 2.000 1.500 1.250 1.000 0.750 0.500 0.250 0.167
2.2 Experimental Air Velocities


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2.3 TFD Flange Mount BC Airfoil Blower Characteristics




3. NUMERICAL ANALYSIS MATLAB CODING
close all;
clear all;
clc;
h = 131.654; % heat transfer coefficient
Tinf = -23.; % ambient temperature
As = .0050265482; % surface area of ball
rhoS= 7800; % density of steel
Vs= 3.351e-5; % volume of ball bearing
vb= 0.2; % velocity of conveyor belt
cp= 450; % specific heat of steel
e= 0.9; % emissivity of steel
sig= 5.67e-8; % Stefan-Boltzmann constant

%comment out '+(e*sig*(T^4-Tinf^4))' to neglect effects of radiation
rightterms = @(x,T)(-As/(rhoS*Vs*vb*cp))*[(h*(T-Tinf))+(e*sig*(T^4-Tinf^4))];
[x,T]=ode45(rightterms,[0,20],500.);

plot(x,T);
title('Temperature of Ball Bearing, Convection')
xlabel('Length of conveyor belt (m)')
ylabel('Temperature (C)')
fprintf('Distance, m Temp, C\n')
fprintf('%8.3f\n', [x'])
fprintf('%11.3f\n', [T'])
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