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What is bearing?

Bearing is a component used to support the long shaft such that they do not
bend and rotate with minimum friction. The different bearing parts are:
Bearing Components
(Deep Groove Ball Bearing)

Seal Rolling Elements Inner Ring


Cage
Outer ring Seal

Ball and Roller Bearing Ranges


Ball bearings + Roller bearings

Deep Angular Self- Cylindr Tape Needl Spheri


groove contact aligning ical r e cal
There are different types of bearings used in any automobile industry.
The different types of bearings used here shown above.

These different bearings may be mounted by more than one method.


These methods depend on the shape of the shaft over which the bearing is to
be assembled and on the kind of fit required between the inner ring and the
shaft. These methods are as follows:

1. The bearing is forced over the shaft with the help of press or with
mandrel and gulla. For too large bearings the force required to assemble
the bearing may become too large hence the bearing is enlarged by
heating and then assembled. Once it is cooled the desired interference fit
it obtained. A care must be taken while pressing the bearing that the load
should not get transferred through the rolling elements. To ensure the
safety of the rolling elements, the mandrel should be such that it exerts
the load on both the inner and the outer rings. Or the mandrel must press
the inner race when the bearing is assembled on shaft and the outer race
in case the bearing is assembled in the housing.
2. The second method is followed when the shaft over which the bearing
has to be assembled is tapered. Bearings with the tapered bore are
mounted in the shaft by means of adapter or withdrawal sleeves or are
seated directly on the tapered journal. Reliable mounting is reached either
by pressing the inner ring by a nut, or by sufficient inserting of the
sleeve. In both cases the inner ring expands and the bearing radial
clearance decreases. For this kind of shaft the inner race of the bearing is
of special kind provided with adapter sleeve.
3. Third method is used when the inner race must be loosely fit with the
shaft. To keep the bearing in the position the screw is fastened on the
tapped hole provided in the shaft. The screw is the integral part of the
inner sleeve of the bearing.

In Eicher we have only cylindrical bore, interference fit kind of bearing


assemblies. So, only first kind of mounting method are followed. The
different sizes of the bearings are not too large either hence the bearings are
assembled with the help of pneumatic presses or with the help of mandrel
and gulla.

Different Mounting Methods

Interference fit Adapter sleeve Set screw locking


(Cylindrical bore) (Tapered bore) (Wider inner ring;loose fit)

Internal Clearances
Bearing clearance is the value of one bearing displacement length of
assembled bearing with respect to the other ring from one end position to the
other one. The displacement can be in radial direction (radial clearance) or
axial (axial clearance).
In the mounted bearing smaller radial clearance can be found than the
same bearing had before mounting. Radial clearance reduction is caused by
interference of the bearing rings on the shaft and in housing bore and thus it
depend on selected tolerance of bearing seating surface diameters. The radial
clearance of the mounted bearing is shown in the figure below:

Radial
cleara
nce

Clearance for standard designed bearings is determined so that one of


the bearing rings can be fixed, what is sufficient for most operation
conditions in the arrangement. For special arrangements with different
requirement on the radial clearance bearings with various radial clearance
designated c1 up to c5 are produced.
Values for various internal radial clearance according to the ISO 5753
are as shown:
Correct Fits

Tolerance range
for bearings
manufactured to
ISO

Certain precautions that must be taken care of while


assembling bearing are:
 The procurement of bearings must follow FIFO system.
 The bearing must be stored in clean and dry place
 The bearing must be unwrapped as late as possible, ideally just before the
assembly.
 The assembly of bearing on shaft requires the pressing of bearing through
the internal race or by pressing of shaft.
 Pressing outer race must do the assembly of bearing in the housing.
 There is some minimum radial internal clearance, proposed by the
bearing manufacturer, that must be maintained for the maximum life of
the bearing.
Location
There are no.of locations where bearings are assembled either on shaft or on
housing. The pressing of bearing is being done by two methods.
PTO BRG ASSEM. PRESS
 Using pneumatic presses
 Using gulla and mandrel.
The various locations where presses are used to press the roller bearing are:

Sr.No. Location Type of assembly


1 PTO shaft sub-assembly Bearing on shaft
2 Bearing housing(differential) Bearing in cylindrical hsg
3 Crown wheel Bearing on cylindrical
projection
4 Left and right cover Bearing in housing
5 Intermediate shaft Bearing on shaft
6 Layshaft Bearing on shaft
7 Axle tube (bigger g2 models) Bearing in housing
BRG. ASSEY. INTER. SHAFT BRG PRESS. AXLE TUBE

Theory:
Little consideration will show that within the tolerance limits the shaft
and bearings can have clearance to interference fit. Thus there is every
possibility that the bearing and shaft (housing) may distort after the bearing
is assembled onto it. Let us consider the worst case where the internal
diameter of bearing is minimum and the diameter of the shaft is maximum.
Or for that matter, the outer diaameter of the bearing is maximum and the
diameter of the seat in the housing is minimum. Now as the bearing is
pressed both the shaft and the bearing get distorted. The bearing expands and
the shaft contracts. Because of this the normal contact pressure is generated
at the mating surface of bearing and shaft. As the bearing distorts (inner race
expands) the radial internal clearance reduces and this being the worst case,
the radial clearance must be minimum. This minimum internal clearance
must be greater than the minimum clearance specified by the manufacturer.

Problem statement:
The challenge is to ensure that the internal clearance is more than the
minimum internal clearance in each and every assembly delivered further.

Requirement:
To ensure the minimum internal radial clearance, the pressing load
required for the assembly of the worst case must be calculated and the
pressing machines must be limited to that value.

When the bearing and the shaft are distorted the tangential and radial
stresses are developed which are the functions of the distortion. They cause
the normal contact pressure between the bearing and shaft. This pressure
generates the friction force that opposes the assembly of the bearing pressing
on the shaft. This is the limiting force required for the assembly of bearing
on shaft. So, we calculate the limiting force for each station and adjust the
press according to that load. This ensures the maintenance of the minimum
internal radial clearance.

Now the question arises how to calculate the required pressing load.

Derivation:
Consider the thick walled cylinder
The figure illustrates the general case of a radially loaded
thick-walled cylinder in that it is subjected to an internal
pressure pi. Since the loading is two dimensional, only
plane stresses will be involved.
When sin(d/2) is replaced by d/2, the equation of
equilibrium of radial forces acting on an element of length
dl is:
r(r ddl) + 2t(drdl)d/2 – (r+dr)(r+dr) ddl = 0 …………(1)
After dividing by rddldr and dropping one term of higher-order differential,
this expression reduces to:
(t-r)/r - dr/dr = 0 ………………………………………(2)
According to the sign convention followed here, all the tensile stresses
are positive and compressive stresses are negative.
Equation (2) involves two unknown variables t and r. These
variables can be expressed in terms of respective strains and the relation of
strains and known quantities can be invoked.
Assuming a homogeneous isotropic elastic material, the only possible
displacement of an element of material is radial, as shown below.
U+du
assuming the element subtends the same angle u dr
before and after displacement. r d
The radial dimension of the element dr increases
during displacement by the amount du, while the
tangential element dimension rd increases by amount u d.
hence the strains involved are:
r = du/dr …………………………………………..(3)
t = u/r …………………………………………..(4)
and also r = (1/E)(r-t) …………………………….(5)
t = (1/E)(t-r) …………………………………..(6)
where E is the young’s modulus of material and  is the poison’s ratio.
From (5) and (6) we get:
t = (E/1-2)(t +r) and ……………………………(5a)
r = (E/1-2)(r +t) ……………………………(5b)_
from (3), (4) and (5)(6) we get
t = (E/1-2)(u/r+du/dr) and …………………………(7)
r = (E/1-2)( u/r+du/dr) …………………………(8)
putting (7)&(8)in the differential equation (2) we get
d2u/dr2 + du/rdr – u/r2 = 0 …………………………(9)
 d2u/dr2 + d/dr(u/r) = 0
integrating once we get
 du/dr = - u/r + c1
 rdu/dr = - u + rc1
 d(ru) = rdrc1
again integrating once we get:
ru = r2/2c1 + c2
 u = r/2c1 + c2/r …………………………(10)

substituting equation (10) in (5a) and (5b) we get


t = k1 + k2/r2 ………………………….(11)
r = k1 – k2/r2 ………………………….(12)
where k1 = Ec1/2(1-)
and k2 = Ec2/(1+)
invoking the boundary conditions:
(1) r = -pi (since the pressures are compressive) at r = ri and
(2) r = -po (since the pressures are compressive) at r = ro
Applying the boundary conditions in equation (12) we get
k1 = (piri2-poro2)/(ro2-ri2)
k2 = (pi-po)ro2ri2/(ro2-ri2).

Now in our case either the cylinder is internally loaded or externally loaded.
Both these cases can be derived as the special cases of the previous general
case.
First we consider the cylinder with internal pressure only
Stresses for this case are obtained by putting po = 0 in (11)&(12):
t = (piri2/ro2-ri2)(1+ro2/r2)
r = (piri2/ro2-ri2)(1- ro2/r2)
k1 = piri2/(ro2-ri2)
now (t)r=ro = 2k1
and (t)r=ri = t,max = hk[1+(ro/ri)2]
or
t max = pi(ro2+ri2)/(ro2-ri2)

Now similarly incase the cylinder is acted upon by the external pressure
only:
Pi = 0 therefore the stress equations become
t = -(poro2/ro2-ri2)(1+ri2/r2)
r = -(poro2/ro2-ri2)(1- ri2/r2)
k1 = -poro2/(ro2-ri2)
(t)r=ri = 2k1
(t)r=ro = k1 [1+(ri2/ro2)]
or (t)max = -po(ro2+ri2)/(ro2-ri2)

Now we come back to the contact pressure, which we require to calculate


between the shaft and bearing.
For the outer cylinder, the radial and
tangential stresses at radius b will cause
tangential strain to which corresponds
to an increase in circumference of
2bo or an increase in radius of bto.
When this increase in radius is designated as
o = bo = b/o(to-ro) …………(a)
stress  ro is equal to –p. with appropriate substitutions
to = p(c2+b2)/(c2-b2)
Substitution of the above into eq.(a) gives
o = bp/Eo[(c2+b2)/(c2-b2)+o]
Similarly,
i = -bp/Ei[(b2+a2)/(b2-a2) - i]
where subscript I denotes inner cylinder and o denotes outer cylinder.
Negative sign in internal cylinder denotes that deformation is directed
towards the center.
The total radial interference fit  (half the diametral interference fit) may be
expressed as:
 = 0-I = bp/Eo[(c2+b2)/(c2-b2)+o] + bp/Ei[(b2+a2)/(b2-a2) - i].

Where:
  is the total distortion(radial) in bearing +shaft (in mm)
 b is the nominal shaft diameter (in mm)
 p is the contact pressure (Mpa)
 Eo is the young’s modulus of the outer component (Mpa)
 Ei is young’s modulus of inner component (Mpa)
 c is the outer diameter of outer component (in mm)
 a is the inner diameter of inner component (in mm)
 o is the poison’s ratio of the material of outer component
 i is the poison’s ratio of the material of inner component

Let the area of contact of bearing and shaft be A


The coefficient of friction is u.
Therefore the frictional force is p*A*u.
This is the frictional force that must be opposed by the press.
Calculation of load at different location

STATI MATERIA Young’s Poisson’ Max total Shaft Contact Frictional


ON LS OF modulus s ratio tolerance dia pressure force
PARTS (=.5)
PTO SAE 2.04*10e1 .3 .023 35 27 MPA 2000
s/a 8620h&en 1&2.o8*1 KGF
31(BRG) 0e11
Interm SAE 8620h 2.04*10e1 .3 .028 40 26 MPA 2200
ediate & en31 1&2.o8*1 KGF
shaft 0e11

The calculation of the bearing pressing load is not required in the case of
taper roller bearing. The reason being, the taper roller bearing must be
assembled under the pre-defined pre-load. The manufacturer of the bearing
determines this load. The outer race and the inner race is assembled in the
respective housings. Then the two housings are coupled to each other with
the help of bolts and screws. These screws are torque to certain specified
limit and under this particular load the required pre loading is achieved. Now
even if the respective races are pressed under higher load and the distortion
is more than normal, while pre loading under specified torquing, the
interference is automatically adjusted and the bearing performance is not
effected.

Status:
The pneumatic presses have been adjusted according to the calculated load
and they are working successfully.

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