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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.
Introduction In a sleeve bearing, a shaft or journal, rotates 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 builtin, a bronze bearing with ring oiling, solid lubricant film or grease lubrication may be satisfactory
CLASSIFICATION
Radial bearings
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.
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.
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.
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 viscosity any one of thesemay prevent the buildup of a film thick enough for full-film/ hydrodynamic 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.
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
Design Considerations Values either given or are under the control of the designer are
1. 2. 3. 4. The viscosity The load per unit of projected bearing area, P The speed N 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. 2. 3. 4. The coefficient of friction f The temperature rise T The volume flow rate of oil Q The minimum film thickness h0
PETROFFS EQUATION:
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
Contd
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 B A defines stable lubrication because variations are self-correcting. Region to the left of line B A 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
e An eccentricity ratio, = c
h0 h0 = c e =1 c
Significant Angular Speed It has been discovered that the angular speed N that is significant to hydrodynamic film bearing performance is
N = N j + Nb 2 N f
The Relations of the Variables Albert A. Raimondi and John Boyd, of Westinghouse Research Laboratories, used an iteration technique to solve Reynolds hydrodynamic equation charts are used to define the variables for lengthdiameter (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.
Viscosity Charts: I
Fig. 12.12
Viscosity Charts: II
Fig. 12.13
Fig. 12.16
h0 = minimum film-thickness (mm) Eccentricity ratio, e = eccentricity (mm), c= radial clearance (mm)
e = c
Fig. 12.17
Fig. 12.18
Fig. 12.19
Fig. 12.20
Fig. 12.21
Chart for the terminating position of the lubricant film and the position of maximum film pressure.
Fig. 12.22
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.
Fig. 12.24
In starting under load there is metal to metal contact, abrasion, and the generation of wear particles between journal and bushing, which, over time, can change the geometry of the bushing, W st
ld 2 . 068 MPa
Design load factor is used for different load applications except in starting load calculation. design factor , nd 2
PROBLEM A full journal bearing has a shaft diameter of 80.00 mm with a unilateral tolerance of 0.01 mm. The l/d ratio is unity. The bushing has a bore diameter of 80.08 mm with a unilateral tolerance of 0.03 mm. The SAE 30 oil supply is in an axial-groove sump with a steady-state temperature of 60C. The radial load is 3000 N. Estimate the average film temperature, the minimum film thickness, the heat loss rate, and the lubricant side-flow rate for the minimum clearance assembly, if the journal speed is 8 rev/s.
PROBLEM (12.11): A full journal bearing has a shaft diameter of 80.00 mm with a unilateral tolerance of 0.01 mm. The l/d ratio is unity. The bushing has a bore diameter of 80.08 mm with a unilateral tolerance of 0.03 mm. The SAE 30 oil supply is in an axial-groove sump with a steady-state temperature of 60C. The radial load is 3000 N. The rise in film temperature is 100C and estimate the minimum film thickness, the heat loss rate, and the lubricant side-flow rate for the minimum clearance assembly, if the journal speed is 8 rev/s.