Bearings and Their Application

Have you ever wondered how machinery functions without rapidly wearing out? Without the use of
simple yet complex mechanical components called bearings, many of our machines would constantly
need repaired due to friction (the force resisting relative motion of two or more surfaces) between
moving components. Friction between two surfaces can be greatly reduced if the surfaces are
enabled to roll over each other rather than slide directly on top of one another. A bearing is a
mechanical device whose function is to support a load, typically applied to a shaft, whilst allowing
relative motion with minimal friction between two elements of a machine. Friction is minimized
between the two elements of a machine by allowing rolling action through point, line or fluid contact
created by a bearing. Bearings typically are cylindrical in shape and consist of an outer race (outer
surface), an inner race (inner surface), and either roller elements or lubricating fluid.

Types of Bearings

There are two major categories of bearings: roller

element bearings (REBs) and hydrodynamic bearings.
Almost any machine consists of both roller element
bearings and hydrodynamic bearings. However, each
type of bearing is unique to its application. Though
bearings can be of any size depending on their
application, most bearings an individual will encounter
during their daily lives range from about one half inch
in diameter to about six inches in diameter. Bearings,
manufactured out of metal products, typically consist of
high strength steel components.

Roller Element Bearings

The relative motion of REBs is a rolling movement of

components. As shown in the Figure 1, REBs contain
small components designed to roll between the inner
and outer rings (as labeled in Figure 1). Typically these small components, called roller elements, are
spherical or cylindrical (as is the case is Figure 1) in shape. Spherical roller elements provide point
contact between the inner and outer races while cylindrical roller elements provide line contact. The
line contact created by cylindrical roller elements allows the applied load to be distributed across a
larger area. Therefore, cylindrical REBs can handle much larger loads than spherical roller element
bearings.

In addition to the rolling elements, REBs are always packed with grease, typically silicone grease,
which serves as a lubricant. Silicone grease also serves as a stiffening agent as its viscosity
(resistance to flow) increases exponentially with pressure. Since REBs are typically sealed they
build up internal pressure proportional to the speed of the rotational motion produced by a shaft. This
pressure induces the impressive difference in viscosity of the grease making it essentially as stiff as
the metal it separates!

Just as a bearing serves to extend the life between two rotating mechanical parts, the stiffness of
silicon grease serves to extend the life of a bearing by lubricating and protecting a bearing’s
components. In fact, if a shaft is rotating fast enough the roller elements will build up enough
pressure in the bearing such that the grease separates any direct contact and fills the gaps between all
the components of the bearing. Ideally one would want a bearing to function in this way all the time
to minimize wear. However, many applications involve variable speeds. A good example is a wheel
bearing for a car whose speed varies often unless a driver is maintaining a constant speed.

Hydrodynamic Bearings

Hydrodynamic bearings (also called journal bearings)

work much like roller element bearings though they do not
contain rolling elements. Their function depends on a fluid
film which is contained between what are known as a
journal (the rotating shaft) and a sleeve (bushing) as shown
in Figure 2. The relative motion of a hydrodynamic
bearing is a sliding motion. Hydrodynamic bearings are
highly reliable however they can only be used in high and
continuous speed applications. The same idea behind the
stiffening of silicone grease in REBs applies to
hydrodynamic bearings except hydro-bearings contain a
viscous fluid such as oil. As shown in the progression of
figures 3(a), 3(b) and 3(c), the increase of rotation speed of the shaft creates a “climbing effect” of
the journal on the inner surface of the sleeve. With each increase in rotational speed, more and more
oil adheres to the journal surface causing a wedging action of the oil between the journal and the
sleeve. The wedging action builds up pressure and once a critical speed is reached, the contact zone
between the journal and the sleeve is eliminated and replaced by the oil; significantly reducing the
overall friction produced by the system.

Bearing Application and Loads

Many applications and applied loads require different types of bearings. REBs are typically used in
low and intermittent speed applications. Light to moderate loads can safely be applied to roller
element bearings. As the load is applied the rollers begin to contact the inner and outer races. Until
enough rotational speed is produced by a shaft, contact between the components will remain causing
light to moderate amounts of wear. Applications consisting of variable speeds and variable loads
often contain REBs because of their versatility. Overloaded REBs however, will rapidly wear out due
to the overloaded contact between their components; a recipe for severe wear. REBs are used in any
portion of a machine that involves rotational motion. The most simple of example of an REB is a hub
(center of a wheel which rotates about a shaft) for a wheel that is supposed to spin freely. Take for
example a bicycle wheel; an REB is placed at the hub of the wheel to allow the wheel to rotate about
an inner shaft at variable speeds.

Hydrodynamic bearings, due to their use in high speed applications, can support high loads without
allowing contact between the journal and the sleeve. The function of the fluid in a hydrodynamic
bearing allows for a very long life expectancy of the bearing. However, incorrect viscosity or
adhesive properties of the viscous fluid being used can cause substantial problems in a hydrodynamic
bearing due to a potential lack in ability to create physical separation of the journal and the sleeve.
Without separation between the journal and the sleeve, the friction produced from the sliding of
metal-on-metal contact between the journal and the sleeve would severely wear out the bearing. With
the proper choice of viscous fluid and the correct high speed application, hydro-bearings prove to be
highly reliable. In fact the turbine shafts of most jet engines used on commercial airplanes, products
held to high standards of reliability, are supported by journal bearings. Though shafts of jet engines
rotate at very high speeds, even the idling speed of a crankshaft in an average automobile engine
rotates fast enough to invoke the use of a journal bearing.

Conclusion

Bearings are a significant part of mechanical systems and without them mechanical parts would
constantly wear and need replaced. After a bearing is installed on a piece of machinery variable
loading conditions are applied to it. An REB will carry a rotational load usually involving the motion
of an external object around an axis (or center) such as a wheel or a pulley mounted on a shaft; each
of which involve moderate loads and variable, moderate speeds. Hydrodynamic bearings will carry
the load of heavy, high speed, rotating components about a mounted shaft. No matter what type of
bearing is being used; as the shaft increases in rotational speed the journal (of a hydrodynamic
bearing) “climbs” the inner surface of the sleeve. The roller elements of an REB perform this same
climbing effect on the inner and outer races of an REB. With each increase in rotational speed, more
and more lubricant adheres to the journal surface (or roller elements) causing a wedging action of the
lubricating fluid between the journal and the sleeve (or the components in an REB). Once a critical
speed is reached, the wedging action has built up enough pressure such that the contact zones
between the bearing components are eliminated and replaced by the lubricant; significantly reducing
the overall friction produced by the system. Next time you are pedaling your bicycle be aware of the
smooth frictionless rotation of each rotating component allowed through the function of multiple
bearings.