2

2
ro2 + rf2
r
+
r
h
s
i
f
r = rf p f

+
+
2
2
2
2
Eh Es rf ri
Es
Eh ro rf

Through interference fit torque can be

transmitted,, which can be estimated
with a simple friction analysis at the
interface.
= coefficient of
Ff = N = p f A
friction

Ff = ( p f d f L)

Torque T =
11/19/2011

pf d L
2

Abrasion

Adhesion
1

C.A.Coulomb 1781
1)Clearly distinguished between static & kinetic friction
)
at discrete ppoints.
2)Contact
3)Friction due to interlocking of rough surfaces

4)No adhesion
5)f func(v)
11/19/2011

PLOUGHING Effect
Eff t
Assume n conical asperities of hard
metal in contact with flat soft metal,
vertically
y project
p j
area of contact:

A = n 0.5 * r

W = n(0.5 * r ) H
2

11/19/2011

cot

F = (nrh) H

Slope of real surfaces are always less

than 10 (i.e. > 80), therefore <
01
0.1.
3

ADHESION Theory

Two surfaces are pressed together under load W.

Theyy deformed until area of contact ((A)) is sufficient to support
pp
load W.
A = W/H.
y, must overcome shear strength
g of
To move the surface sideway,
s
junctions
with force F
F =As
11/19/2011
4

Aim: To reduce shear strength

of interface

LUBRICATION
Process by which the
friction in a moving
contact is reduced. Six
distinct form of
l b i
lubrication
i
are:
Hydrodynamic
Hydrostatic

Elastohydrodynamic
Mixed
Boundary
S lid film
Solid
fil

11/19/2011

11/19/2011

FLUID FILM
BEARINGS

>5

Machine elements designed to produce smooth (low

friction) motion between solid surfaces in relative motion
and to generate a load support for mechanical
components.

Fluid between surfaces may be a gas, liquid or solid.

Word film implies that fluid thickness (clearance) separating

the surfaces is several orders of magnitude smaller than
other dimensions of bearing (width & length).

Successful design requires film thickness to be larger than

the micro asperities on the surfaces, operation without
contact of surfaces.

Operation principles of liquid film bearings are

hydrodynamic, hydrostatic or combination.
11/19/2011

Hydrodynamic

Hydrostatic
4/6/8 pockets

Axial coordinate
11/19/2011

A i l coordinate
Axial
di
8

Hydrodynamic

Hydrostatic

Relative motion between two

mechanical surfaces is utilized to
generate pressure and levitate
one surface relative to other
surface. Self-acting

External source of pressurized

fluid is required to levitate the
one surface and separate it
from other surface
surface.. Costly

Load support is a strong function

off lubricant
l b
viscosity.

Load support is a weak function

of lubricant viscosity.

HDL provides an infinite bearing

life

Infinite life if supporting ancillary

equipments function well

Able to damp the external

vibrations.

Able to control the effect of

external vibration.. Active control

Significant difference in static &

kinetic friction coefficients

Almost same value of coefficient

of frictions.

High relative speed generates

much higher
g
load capacity
p
y&
destabilize the shaft-system.

Very good control on the shaft

position.
p

11/19/2011

Petroffs
Petroff
s
Equation
Friction = Shear Stress * Area

C is radial clearance

F = (Viscosity*
( i
i * V/h)*Area
/h)*
V = 2RN ; A = 2RL
Friction force, F =

* 2RN * 2RL

C
F
Coefficient of friction, =
W
* 2RN * 2RL / C
=
2 RLP
N R
= 2 2
P C

Stribeck
Bearing
characteristic
number

11/19/2011 Coefficient of friction is a function of speed, load and viscosity

10
Conclusion:

Lubricant Viscosity
VI relates viscosity change at 37.8
0c and 98.90c.
Pennsylvanian oil~VI=100
L-U
*100
VI =
gulf coast oil ~ VI=0
VI 0
L-H

11/19/2011

11

Dynamic viscosity, 1cP = 1mPa.s

Kinematic viscosity, 1cS = cP/0.85 (g/cm3)

Variation with Temperature

p

More viscous oil is more susceptible to change in

viscosity with temp.
Walthers equation: Form the basis of ASTM
viscosity temperature chart

l log(
log
l ( + 0.6) = constant
t t c log
l T
Vogels equation: Most accurate; very useful in
engineering calculations
= ke b /(t + ) k gives inherent viscosity.
b has units of temp.
p b increases with increase in viscosity.
y
11/19/2011

12

Temperature Rise
Friction, due to shear of lubricant film,
generates heat (FV)) in lubricant oil and
i
increases
th
the temperature
t
t
off llubricant.
b i
t
Assuming that total generated heat is
carried
i db
by the
th oil
il flowing
fl i
through
th
h bearing
b
i
Heat generated = Heat convected by oil flow
(2 R N )(2 R L )
(2 R N ) = m CP t
C
or

t =

(2 R )3 N 2
C m CP

= 860 kg / m3

C P = 1760 J / kg oC

(2 R )3 N 2
or t =
L

2RN
C
C L CP

( )

8 2 N R
or11/19/2011
t =

( ) C P C

R
= 1000
C

t = 52.2 N
13

t = 52.2 N
t = 783

Assume rotational speed

p
= 900 rpm
p
In hydrodynamic lubrication, increase in viscosity
increases load capacity but also increases
friction. We require Reynolds equation.

SAE
grade

Viscosity in
Viscosity in
t = a e (t a )
mPa s 400c mPa.s
mPa.s
mPa s 1000c

25.5258

10W

32.6

5.57

4.3660

48 7809
48.7809

20W

62 3
62.3

8 81
8.81

6 8982
6.8982

78.3000

SAE 30

100

11.9

9.3177

109 6200
109.6200

SAE 40

140

14 7
14.7

11 5101
11.5101

29.7540

5W-20

38

6.92

5.4184

51 9912
51.9912

10W 30 66.4
10W-30
66 4

10 2
10.2

7 9866
7.9866

60.3693

10W-40 77.1

14.4

11.2752

91 6110
91.6110

10W 50 117
10W-50

20 5
20.5

16 0515
16.0515

11/19/2011

14

Reynolds Equation
A basic pressure distribution equation for Fluid
Film Lub.
In 1886, Reynolds derived for estimation of
pressure distribution in the narrow, converging
gap between two surfaces.
surfaces
Reynolds equation helps to predict hydrodynamic,
squeeze, and hydrostatic film mechanisms.
Reynolds' equation
h 3 P h 3 P

+
= 6 (U 1 + U 2 )h + (W1 + W2 )h + 2(Vh V0 )

x x z z
z
x

11/19/2011

15

U1

U2=0

No ppressure development
p
within the pparallel surfaces.
U1

11/19/2011

U1

16

Pressure driven flow

11/19/2011

17

Small element of
Fluid with sides
dx, dy, and dz

Force balance : pdy.dz + +

dy dx.dz = p + dx dy.dz + dx.dz
y
x

u
For Newtonian flow =
y
P u
x

y y

11/19/2011

18

u P
On integration :
=
y + C1
y x

P u
=
x y y

P y 2
u =
+ C1 y + C2
x 2
Using boundary conditions : y = 0, u = U 2 ;
y = h, u = U 1

U 2 = C 2 ,

(U1 U 2 ) P h

= C1

x 2
h
y 2 yh P
y

(
)
u =
+ U1 U 2 + U 2

h
2 x

11/19/2011

Check !!!

19

Flow rate in x - direction per unit width :

h

q x = u.dy
0

h 3 P
h
qx =
+ (U1 + U 2 )
12 x
2

Check !!!

Similarly flow rate in z - direction

h

q z = w.dy
d
0

h 3 P
h
qz =
+ (W1 + W2 )
12 z
2

Reynolds equation is derived using mass continuity equation

q x
q z
(
)
=0
V
V
+ h 0 +
x
z
11/19/2011

20

Reynolds' equation
h 3 P h 3 P

+
= 6 (U1 + U 2 )h + (W1 + W2 )h + 2(Vh V0 )

x x z z
z
x

Stretching action

U1i

U1ii

U1iii

x
11/19/2011

21

Reynolds' equation
h 3 P h 3 P

+
= 6 (U1 + U 2 )h + (W1 + W2 )h + 2(Vh V0 )

x x z z
z
x

Wedge
action
(inclined
surfaces

h2

h1
11/19/2011

22

Reynolds' equation
h 3 P h 3 P

+
= 6 (U1 + U 2 )h + (W1 + W2 )h + 2(Vh V0 )

x x z z
z
x

h0

h1

h2

t = t0

t = t1

t = t2

t0 < t1 < t2
11/19/2011

Can caarry
High looads
for shhort
duration

h0 > h1 > h2

Squeeze
q
action
(bearing
surfaces move
perpendicular
di l to
each other)

23

Reynolds' equation
h 3 P h 3 P

+
= 6 (U1 + U 2 )h + (W1 + W2 )h + 2(Vh V0 )

x x z z
z
x

1 P

= 6(U1 + U 2 ) h
Simplification I : h
z z
x
3

z
x

h 3 P

= 6(U1 + U 2 ) h
Simplification II :
x x
x
11/19/2011

24

H d St ti Bearings
Hydro-Static
B
i
(HSB)
Completely removal of wear and reduction of
coefficient of friction to 1/500.
Surfaces can be separated by full fluid film even at
zero speed.
No problem with micro roughness and waviness.

Zero friction at zero speed.

Useful feature for large size telescopes and radars.

High stiffness
1/ 3
h

W
Oil film thickness varies as cube root of load.
Why
Wh nott every bearing
b
i
is
i based
b
d on Hydrostatic
H d
t ti mechanism
h i
High pressure supply Reliability & life of high pressure oil lines
are always in doubt.
11/19/2011

25

Elementary 1-D Analysis

Assume a shaft of
radius Ro is located
co-axially with a
circular recess of
radius Ri.
Assume all the oil
in recess is at the
supply pressure Ps.

11/19/2011

26

h dp
Elemental flow rate: q = 12 dr .rd
3

Reff tto
R
slide 20

If flow is axisymmetrical,
y
, and radial flow rate
is constant, then flow rate:
h 3 dpp
Q=
.r .2
12 dr
If film thickness is constant,
constant then on
integration:
h 3 p
= Q (log r + C1 )
6
11/19/2011

27

 Using two boundary conditions to find

unknown values of C1 and Q
p = ps

log

R0

log

R0

in the region R 0 r Ri

Ri

Load carrying capacity:

W = ps .

Ri2

Ro 2

+ p(rd ) dr
Ri 0

Substituting expression of p and rearranging

Ri2
1

2
R
o

W = ps . Ro2

Ro
2
.
log
R

11/19/2011

1 r 2
1

W = C1
2. log 1
r

28

load vs ratio
22
20
18

C1 = 10

16

load

14
12
10
8
6
4
.1

.2

.3

.4

.5

.6

.7

.8

.9

ratio

W = ps . Ri2 +

Ro 2

p(rd )dr

Ri 0

h03 ps
1
Q=
6 llog((1 / r1 )

11/19/2011

1
Q = C2
log(1 / r1 )

29

1
Q = C2
log(1 / r1 )

flow vs ratio
240
220
200
180
160

flow
w

140
120
100
80
60
40

C2 = 10

20
0
.1

.2

.3

.4

.5

.6

.7

.8

.9

ratio

Generally we require high load capacity but low flow rate.

rate

11/19/2011

30

Power loss: consists of pumping

power and friction losses.
Pt = Ph + Pf

F = A

Ph = Q.Ps
R04 Ri
Pf =
1

2 h0
R
0

F =

U
h0

r
h0

A(r )

Pf = Fr Pf =

2
h0

R0

3
2

r
dr

Ri

Ri 2

1
2

Pt =
Ps +
1
6 log(
g( R0 / Ri )
2 h0 R0

h03

R04

Generally we require high load capacity, low flow rate and low
power loss.
loss
11/19/2011

31

Example: W = 1000 N, =5 rpm, R0=100 mm, Ri=50

mm, =0.01 Pa.s. Optimize minimum film thickness for
minimum power loss
4

Ri 2
1

Pt =
Ps +
1
6 log( R0 / Ri )
2 h0 R0

h03

Ri2
1

2
R
o

W = ps . Ro2

Ro
2
.
log
R

= 2 * 5 60 = 0.5236 rad/s
d/
Ps =

1000 2. log(2)
Ps = 58,824 Pa
2
2
* 0.1 1 0.5

ho min power loss = 26.8 micron

11/19/2011

R04

Pt = C1h03 + C2

h0

C1 = 2.614 *1011 N/(s.m 2 )

C2 = 0.404 *10 6 N.m 2 / s
32

Short Static
Hydrodynamic Bearing
1 P

= 6(U1 + U 2 ) h
h
z z
x
3

2 P 6U dh
= 3
2
z
h dx
dp 6U dh
= 3
z using max pressure condition dp/dz = 0 at z = 0
dz
h dx

3U dh 2 L2
z
p= 3
h dx
4
11/19/2011

using p = 0 at z = L/2
33

Film thickness, h, depends on geometry of tribo-pair.

tribo pair. For
example, in journal bearing h = Cr + e cos
Using expression of h in following equation
3U dh 2 L2
z
p= 3
4
h dx

; dx = R d ; =

e
Cr

2
3U
sin 2 L
p= 2

z
3
4
R
Cr (1 + cos )

11/19/2011

34

Load capacity of short journal

bearing

Load component in direction of line of centres

L2

UL3 2 2
W = p.( Rd .dz ). cos W =
2Cr2 1 2
0 L 2

Load component perpendicular to line of centres

L2

Wr = p.( Rd .dz ). sin Wr =

0 L 2

W =

W + Wr2
2

UL

4Cr2 1 2

UL

=
4Cr2 1 2

Wr
1 2
tan =
tan =
W
4

11/19/2011

1/ 2

16 2
2 1 + 1

35

Locking of Journal
Position

=1
=0
W = Max value

=0
=

2
W =0

0 < <1
0 < <

2
0 < W < Wmax

Journal OD

Bearing ID
11/19/2011

36

Lesser the attitude angle, better the stability of bearing.

eccentricity ratio vs. attitude angle
90
80
70
Attitude angle
e

60
50
40
30
20
10
0
0

.1

.2

.3

.4

.5

.6

.7

.8

.9

Eccentricity ratio
11/19/2011

37

Friction force in Journal Bearing

Petroff equation (explained on slide 10)--- inaccurate

U dp h
= +
; F = dA
h dx 2
L/2
U

F = + 0 Rd .dz
h

L / 2 0

F=

2ULR
Cr 1 2

h = Cr + e cos

UL

W =
4Cr2 1 2

1/ 2

16 2
2 1 + 1

If 0, F Petroff solution
11/19/2011

38

Raimondi & Boyd Method

Reynolds' equation for static loading
h 3 P h 3 P
h

+
= 6U

x x z z
x

R Ns
Sommerfeld number S =
C p
N s rotation
t ti for
f second
d
2

Dimensionless number

11/19/2011

39

L/D

(R/C)f

Q/(RCLNs ) Qs / Q

p/pmax

.631

.2

74

12.8

3.596

.28

.529

.264

.4

63

5.79

3.99

.497

.484

.121

.6

50.6

3.22

4.33

.68

.415

.045

.8

36.2

1.7

4.62

.842

.313

.019

.9

26.5

1.05

4.74

.919

.247

2.03

.2

75

40.9

3.72

.318

.506

.779

.4

61.5

17

4.29

.552

.441

.319

.6

48

8.1

4.85

.73

.365

.092

.8

33.3

3.26

5.41

.874

.267

.031

.9

23.7

1.6

5.69

.939

.206

7.57

.2

75.2

153

3.76

.33

.489

2.83

.4

60.9

61.1

4.37

.567

.415

1.07

.6

46.8

26.7

4.99

.746

.334

.261

.8

31

8.8

5.6

.884

.24

.9

21.9

3.5

5.91

.945

.18

0.5

0.25

11/19/2011

.074

40

 Question: Estimate friction coefficient

and minimum film thickness of a full
cylindrical hydrodynamic bearings
required for shaft of 50 mm dia
rotating at 1500 rpm
rpm. Assume applied
load is 5 kN, bearing length is 50
mm radial clearance is 25 microns,
mm,
microns
and lubricant viscosity is 25 mPa.s (at
ambient
bi t ttemperature).
t
)
= 860 kg / m3

C P = 1760 J / kg oC
11/19/2011

t = a e

(t a )

41

Clutches & Brakes

Difference between coupling, clutch &
brake.
Maximize friction (uniform)
g
connection/disconnection
Smooth,, gradual
Minimize Wear (if mechanical)

Design targets:
Required friction torque.
Actuating Mechanism

Heat dissipation.
Desired life.
11/19/2011

42

Various Types
yp of
Clutches & Brakes
P

11/19/2011

Mating frictional surfaces

transmitting torque
Actuating mechanisms
Centrifugal
Magnetic
Hydraulic
Pneumatic

P
43

Clutches
Cone clutch is installation.
However, disk clutch a number
off advantages
d
t
over cone clutch.
l t h

Large frictional area

in relatively small
area.
More effective heat
dissipation.
Simple construction.
11/19/2011

44

Aim: Obtain expression of axial

force F necessary to produce a
certain torque with pressure
distribution.
Uniform pressure
ro

F = p 2r dr
d
ri

ro

F = p 2r dr = p (ro2 ri 2 )
ri

ro

T =
ri

11/19/2011

2
f r p 2r dr = f p (ro3 ri3 )
3

Friction based brakes

Friction mat.

f
Dry

Oil

Pmax

((MPa))

Tmax
((C)
C)

1-2

230

0.35-0.69

230

1-2

300

Molded

0.25-0.45 0.06-0.09

Woven

0.25-0.45

Sintered

0.15-0.45 0.05-0.08

Cast iron/
Hard_steel

0.15-0.25 0.03-0.06 0.69-0.72

0.08-0.1

260

Wet or dry brakes

11/19/2011

46

Laws of Wear
Wear Volume proportional
to sliding distance (L)

True for wide range of

conditions
Wear Volume proportional
to the load (N)

D
Dramatic
ti iincrease
beyond critical load
Wear Volume inversely
proportional to hardness
of softer material

k1 NL
V=
3H
11/19/2011

Transition from mild wear to severe

depends on relative speed,
speed
atmosphere, and temperature.

Two methods to estimate pressure

distribution are:
Uniform wear
Uniform pressure
p

k1 NL k1 pA(Ut )
Wear volume,V =
=
3H
3H
V
k1 p
pU
=
w pU
U
wear rate, w =
At
3H
Constat wear rate mean pi ri = po ro

ro

F = p 2r dr
ri

ro

F = 2 po ro dr
ri

ro

T = 2 f po ro r dr
ri

11/19/2011

Comparison
Tuniform wear = f pmax ri (ro2 ri 2 ) assuming max pressure at ri

2
3
3
Tuniform pressure = f pmax (ro ri )
3
Tuniform pressure 2 (ro3 ri3 )
Ratio =
=
2
2
Tuniform wear
3 ri (ro ri )
2 (R 1)
Ratio =
3 (R 2 1)

Torque ratio vs dimension ratio

11/19/2011

Torque ratio

1.6
1.55
1.5
1 45
1.45
1.4
1.35
1.3
1.25
12
1.2
1.15
1.1
1.2

49
1.3

1.4

1.5

1.6
R

1.7

1.8

1.9

Friction
mat
mat.

Value of ri to maximize Dry

T

Tuniform wear = f pmax ri ro2 ri 2

dT
=0
d ri

ro
ri =
3

Pmax

(MPa)

Oil

M ld d
Molded

0.250
25
0.45

0.060
06
0.09

1 2
1-2

Woven

0.250.45

0.080.1

0.350.69

Sintered

0.150 45
0.45

0.050 08
0.08

1-2

0.150.25

0.030.06

0.690.72

)
Hard steel
Hard_steel

2
iron/
T = f pmax ri ro2 rCast
N
i

Most
ost o
of automotive
auto ot e clutches
c utc es operate
ope ate
wet. The oil serves as an effective
coolant during clutch engagement.
To compensate reduced coefficient
of11/19/2011
friction, multiple disks are used.

50

ro

F = 2 po ro dr

Disk Brake
2

ri

ro

F = pi ri

d dr

ri

T = f pi ri

ro

r dr d
ri

ro

T = 2 f po ro r dr
11/19/2011

ri

51

Ex: Two annular pads, ri=98mm, ro=140 mm, subtend an

angle of 100, have a coefficient of friction of 0.35, and are
actuated
t t db
by a pair
i off hydraulic
h d
li cylinders
li d
36 mm in
i
diameter. Torque requirement is 1500 N.m. Determine max
contact pressure, actuating force and hydraulic pressure.

CASE I: Uniform wear

2

T = f pi ri

ro

r dr d
ri

F = pi ri

ro

d dr = 18007 N
ri

1500
0.142 0.0982

= 0.35 pi * 0.098 * 100 *

2
180
2

pi = 2506649 Pa
11/19/2011

phydraulic

F
=
= 17690959 Pa
P
2
(0.018 )

52