Professional Documents
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Learning Outcome
When you complete this module you will be able to:
Describe the methods for simple care and maintenance of bearings and their
related lubrication systems.
Learning Objectives
Here is what you will be able to do when you complete each objective:
1. Define boundary and full fluid film lubrication.
2. Sketch and describe shell (sleeve) bearings.
3. Describe the construction and operation of thrust bearings.
4. Describe how to clean and replace roller and ball type bearings.
5. List the causes of bearing failure.
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INTRODUCTION
Since there are a number of types of bearing arrangements, each having its own
operating characteristics, it is necessary to provide lubricants which match the
operating principles of the bearings and the conditions of temperature, humidity,
speed, etc., encountered in various applications.
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Figure 1
Fluid Film Lubrication
In Fig. 1(a) the shaft is not turning and is in contact with the bottom of the
bearing. When the shaft begins to rotate Fig. 1(b), it tends to roll up the side of the
bearing and oil flows in behind and below it. As the shaft speed increases
Fig. 1(c) the oil is forced by the shaft into the wedge shaped space in front of and
below the shaft and enough pressure is produced to separate the shaft from the
bearing surface. At high speed Fig. 1(d) the shaft is forced slightly over to the
right due to the oil pressure.
At high speeds, the oil film separating the shaft from the bearing becomes thicker
due to the increased pumping action of the shaft. As the speed decreases, the film
thickness becomes less until at slow speeds it breaks down and only boundary
lubrication exists.
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Figure 2
Methods of Oil Supply
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The simplest and oldest method of lubricating the bearing is the hand-operated oil
can, Fig. 2(a). This method is only suitable for small bearings which require a few
drops of oil every few weeks or months. Bearings on larger equipment need a
steady oil supply. A feeding device such as the automatic oiler (wick-feed, gravity
feed, etc.) gives a more continuous supply, Fig. 2(b), but the bearing may still run
short of oil if the feeder is not refilled at regular intervals.
A more satisfying solution, quite common on pump and motor bearings, is the
ring-oiled bearing shown in Fig. 2(c). The lower part of the bearing housing is
filled with oil. A ring rides on the shaft through a slot in the center of the upper
part of the bearing. When the shaft rotates, it moves the ring slowly and the ring
picks up oil from the reservoir beneath the bearing and drags it up through the
bearing slot from where it is distributed between the shaft and bearing. Once
through the bearing, the oil drops back into the reservoir.
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Figure 3
Sleeve Bearing
The ability of an oil film to lift and support a heavy load is dependent upon
hydraulic pressure. This pressure is brought about by the pumping action of the
rotating journal or shaft, and any grooves in the pressure area which permit oil to
escape will tend to encourage metallic contact. Also, when bearings are composed
of two or more parts fitted together, any sharp corners at the joints will tend to
scrape the oil from the shaft, and consequently, all corners and edges should be
chamfered or rounded to prevent this scraping action.
The principles of correct design and grooving of bearings may be briefly
summarized as follows:
1.
2.
3.
4.
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5.
6.
Fig. 4 shows the location of oil groove and chamfer in a sleeve bearing.
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Figure 4
Oil Groove and Chamfer
Bearing Failure
One of the first signs of a failing bearing is a rise in its operating temperature.
Another sign is knocking or other unusual noises which indicate excessive
wear. Usually the cause of the bearing trouble is one or more of the following:
1.
2.
3.
4.
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5.
6.
2.
3.
Oil can be allowed to flow from the bearing reservoir and circulate
through an oil cooler away from the bearing assembly before being
recycled through the bearing for further lubrication and heat
removal.
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THRUST BEARINGS
The purpose of a thrust bearing is to prevent a rotating shaft from moving in an
axial direction. A simple type of thrust bearing, known as a collar thrust, is shown
in Fig. 5.
In this type, the collars, which are an integral part of the shaft, have their complete
area pressing against the bearing surface and there is no room for an oil wedge to
be formed. Lubrication is therefore of the boundary type and the load that this
type of bearing can carry is limited.
Figure 5
Collar Thrust Bearing
A more suitable design of thrust bearing has the bearing surfaces in the form of
pads. These pads are free to tilt and thus allow the formation of an oil wedge to
separate the bearing pad from the shaft collar.
Fig. 6 shows two types of tilting pad thrust bearings, the Michell in 6(a) and the
Kingsbury in 6(b).
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Figure 6
Tilting Pad Thrust Bearings
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In the plain or shell bearings, the main purpose of the lubricant is to separate the
surfaces by means of a lubricating film. This film may be microscopic in
thickness as in the case of boundary lubrication, or it may be thick enough to float
the shaft as in the case of fluid film lubrication.
In the lubrication of ball and roller bearings, Fig. 7, the principle is somewhat
different. In this type of bearing, which is also referred to as an antifriction
bearing, the sliding of one surface over the other is largely replaced by a rolling
motion, therefore friction is largely eliminated (hence the name antifriction). The
main purposes of the lubricant in these bearings are:
1.
2.
3.
4.
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Figure 7
Roller Bearing
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The lubricant used may be either oil or grease, depending upon operating
conditions. In general, oil is preferred for the following conditions:
1.
2.
Where speeds are high and the use of grease will produce excessive
heating due to the work done in churning or displacing the grease.
3.
For high operating temperatures. In some cases steam cylinder oil may be
necessary.
4.
Where bearings are located adjacent to other parts which require oil
lubrication.
5.
In applications where speeds are not high and temperatures are not extreme,
greases may be preferred for the following reasons:
1. Grease is less likely to be flung out or to leak from the bearings. This is an
advantage in regard to keeping the adjacent surroundings clean.
2. Where the atmosphere is polluted with impurities, grease provides a better
seal to prevent entrance of these impurities into the bearing housing.
3. Grease is more satisfactory for protecting bearings from corrosion during
idle periods as it does not drain away as oil tends to do.
Bearing Seals
In order to prevent foreign matter (dust, grit, water, etc) from entering the bearing
housing, which would result in contamination of the lubricant, and to prevent the
lubricant from leaving the housing, seals are installed on the shaft where it enters
the bearing housing. These seals consist of felt, synthetic rubber, or leather rings,
enclosed by their own steel casing and sometimes fitted with a light spring to
force the seal against the shaft, Fig. 8.
Fig. 9 shows a seal mounted in the housing of a ball bearing which can be either
oil or grease lubricated.
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Figure 8
Shaft Seals
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Figure 9
Ball Bearing with Seal
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2. Cleaning by Dismantling
The most effective method of cleaning a bearing is to dismantle and remove it
from the shaft. In this way the bearing can be thoroughly cleaned and, in addition,
it can be inspected for signs of wear or failure.
Care must be taken to avoid damage to the bearing when dismantling it. All dirt
must be cleaned from the outside of the bearing and the shaft. The bearing should
not be removed from the shaft by hammering on the inner or outer race. The race
is the ring assembly within which the balls or rollers rotate. More precisely, there
is an inner ring and an outer ring. The ring that rotates freely is called the shield or
separator. The ring that is press-fitted on the shaft or in the housing, as the case
may be, is more precisely called the race. In cases where the shaft and bearing can
be placed in a vice, a safe method is to drive the shaft from the bearing by means
of a brass drift pin and a hammer. This method is illustrated in Fig. 10.
Note that when removing the bearing by this method, parallel steel blocks should
be inserted under the face of the inner race in order that the force will be applied
squarely and no damage due to distortion will result.
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Figure 10
Removing Antifriction Bearing
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2.
3.
Rusting or corrosion.
4.
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Figure 11
Bearing Pullers
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Replacing Bearings
Before installing a bearing on a shaft or in a housing, it is essential that the shaft
or housing be absolutely clean. This ensures that the bearing can be pressed into
place without scoring or scratching.
Fig. 12 shows a method of installing a bearing on a shaft.
The bearing should be smeared with oil and then tapped along the shaft using a
pipe or tube and a wooden striking block and a hammer. The tube should rest
squarely on the inner race so that it will not damage any bearing parts.
In cases where an extremely tight fit is required, the bearing inner race may be
heated in an oil bath or an oven in order to expand it evenly. This heating should
not be carried out with a welding torch or blow torch as this method will produce
uneven heating and distortion.
Figure 12
Bearing Installation
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If the lubricant, such as a grease, forms a hard mass within the bearing, then the
rollers or balls will not be free to move and the bearing will wear. Also, hard
pieces of lubricant will be pressed into the bearing surfaces which will produce
flaking and pitting.
2.
Improper Fitting
If, when pressing a bearing into place on a shaft, the force is applied through the
balls or rollers, then the surface under the balls or rollers will be indented or
nicked. This condition is known as brinelling and will cause eventual bearing
failure.
An improper fitting procedure will also cause cracking or splitting of the bearing
race. This may be due to forcing the bearing onto a shaft which is too large. It
may also be due to the force not being applied squarely to the race during
installation.
3.
Misalignment
Misalignment of a shaft, due to a driving belt that is too tight, for example, will
cause uneven loading of the bearing resulting in flaking of surfaces and excessive
wear.
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4.
False Brinelling
This occurs in stationary bearings that are subjected to vibration. It resembles true
brinelling as described in the section on improper fitting in that it produces
indentations
in the surfaces in contact with the balls or rollers.
5.
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Notes:
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