UNIT - I

Prof. N.Gobinath
SMBS
VIT Chennai

BEARINGS
To support rotating elements (Shaft)
Load transmission
Minimum friction
Arresting degree of freedom, necessary.

SLIDING CONTACT BEARINGS

Design of bearing & housing is simple
Less radial space
More silent in operation
Take more shocks
High speed operation

Friction power loss

Attentive to lubrication
Thrust loads cannot be handled, effectively

BEARINGS TYPE OF LOADS

Radial : Radial loads
Thrust : Axial loads (Propeller of ship)
Radial thrust :

BEARINGS TYPE OF LUBRICATION

Thick film
Thin film
Boundary lubrication

JOURNAL BEARINGS
Journal ??
Full, Partial, Fitted journals
Full journal : To accommodate radial load in any dir.
Partial journal: radial load in definite direction

Rail road cars

Dia. (journal < bearing)

Fitted journal:

HYDRODYNAMIC LUBRICATION

---- Beauchamp Tower concept-----

When sufficient oil is supplied to bearing, pressure

develops when journal rotates inside bearing;
Rotation axis is eccentric with bearing axis;
Load can be sustained by the fluid pressure;

-CONTD.
At rest : velocity = 0
At start : boundary lubrication
After start : Thin film
At running : Thick film / Hydrodynamic

LUBRICANTS
Viscosity
Viscosity Index

Functions:

Low friction
Preventing corrosion
Possible heat removal
Thermal stability and durability
Compatible

Designation

SAE 5W,10W @ -18 C

SAE 10,20,30 @ 100 C

DESIGN PROCEDURE

1.

Journal Diameter

2.

L/D (Based on Machinery & M/c elements)

3.

4.

Allowable bearing pressure

Lub. Viscosity

Determine the pressure

Given Load over the projected bearing area

Identify the Clearance value

(q, ho, T) --- fn.(C)

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CONTD.

5.

Minimum film thickness

L/D value

Clearance factor

Roughness peak factor

rms values of bearing & journal

( Can be obtained from D.Book)

6.

Select S (for the min.film thickness variable)

Find Z @ the working temperature

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CONTD.

7.

Obtain the friction variable @ S

*(D/C)

Find the friction coefficient

(For L/D =1, use chart)

(use Mckees equation when S>0.15)

8.

Heat balance
Heat generated = *W*v (watts)
Heat dissipated = t*A*K (watts)
Check for proper heat dissipation

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CONTD.

9.

Calculate the mass flow rate of lub. Oil

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NUMERICAL
A 100mm diameter full journal bearing supports a
radial load of 5000N acting in the m/c shaft of a
reciprocating compressor.
The bearing is 100mm long and the journal
operates at 400rpm.
Using Raymondi and Boyd curves find

Viscosity of suitable oil

Coefficient of friction
Heat generated
Amount of oil supplied
Temperature rise of the oil
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STEPS TO SOLVE
Dia of journal = 100mm
L/D = 1
Pressure = 0.5 N/mm2

Check for safe value

Find Clearance (for motor / generator appln.)

100 microns

Find minimum film thickness

Find S

Determine Z

Find friction variable

Determine

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CONTD.
Heat generated: ? (watts)
Amount of oil supplied:

Temperature rise of oil

Flow variable (4q/DCNL)

q?
Temp. rise variable (Ct/P)

Select the suitable oil

Viscosity requirement
Temperature requirement

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NUMERICAL 2
A 50mm diameter journal rotates uniformly at 1500
rpm in a lathe turned bronze journal bearing which
is 50mm in length. Temperature of oil is 65C.
Assume the Diametral clearance is 0.1mm
Determine

the max. radial load that the journal can carry

Power loss in the bearing
Hint: choose the appropriate lubricant oil to proceed
further
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ROLLING CONTACT BEARINGS

Prof. N.Gobinath
SMBS
VIT Chennai

ANTI- FRICTION BEARINGS

The load transmission through elements in rolling

contact

Starting friction < running friction

Friction < sleeve bearings

Select the bearing which is already designed

Space (already defined)

Load carrying capacity
Satisfactory life

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ROLLING FRICTION

Different from sliding friction (no tangential forces

cause friction)

Resultant R should pass through the centre ??

Value of P to have a constant motion:

(a/r)*L

Coefficient of rolling resistance r

a depends on wheel material and surface

properties

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TYPES

Single row deep groove ball bearings:

The radius of circular arcs are slightly larger than that of

the balls

Axial loads too can be imposed

High speed, low power loss requirements

Steel shields or rubber seals are used

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CONTD.

Single row angular contact ball bearings:

Radial and angular loads

Contact angles : 15, 25, 30, 40

Larger contact angle larger axial load

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CONTD.

Self aligning ball bearings:

Inner ring has 2 raceways

Outer ring has a single spherical raceway

Its centre of curvature coincides with axis of bearing

Minor angular misalignment due to machining or

mounting will be taken care
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CONTD.

Cylindrical roller bearings:

Line contacts

High radial load & High speed operations

Ribs to restrict axial movement of inner / outer rings

Used as free-end bearings

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CONTD.

Needle roller bearings:

Slender rollers

l/d = 3 to 10

As a result, Do/Di is small -- more rigid

High radial load capacity

Many types dont have inner rings

Rollers are assembled with steel cage

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CONTD.

Tapered roller bearings

Conical rollers
More radial and axial loads

Spherical roller bearings:

Barrel shaped rollers

Outer ring has single raceway

Self-aligning

Heavy and impact loads

Brass cages are used for seal

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BEARING SELECTION

Radial load

Thrust load

Speed

Desired life (hours)

Nature of loads

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BEARING LIFE

No. of revolutions / hours of use @ constant speed,

until the first occurrence of fatigue crack

Nominal / rating life of anti-friction bearings is the

no. of revolutions that 90% of the group of identical
bearings can survive before the evidence of first
fatigue failure

L90 (probability for 90% survival)

L90< L70 < L50

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DYNAMIC LOAD CAPACITY

Bearing operates at high stress levels

Finite service life

Due to different curvatures in axial & radial dirns.

Load for desired service life to be found

Failure curve

29

CONTD.

The basic dynamic load rating (C) can be defined

as that load to which the bearings can be subjected
while achieving a rated life of 1 million revolutions.

Experimental results give, LPk = Constant

k = 3 (ball bearings)
k= 10/3 (roller bearings)
L = Life in million revolutions
P = specific load

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CONTD.

Dynamic load capacity C = [L/L90]1/k.P

P = equivalent radial load

Bearings loads Radial + Axial

Factors influence bearing performance ??

Radial factor

Axial / thrust factor

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RELIABILITY FACTOR

If a bearing group has 90% survival & 10% fail

Reliability of each bearing = 0.9

For a system having n bearings each having the

survival probability as p, then the survival
probability of the system = ?

For a desired life of bearing, need to find the

survival probability
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BEARING MOUNTINGS

33

NUMERICAL ANALYSIS

To what extent the load on a ball bearing is to be

reduced so as to double the expected life?

A bearing is designed to have a life of 1800 hours

with a reliability of 99%. What is the rated life of it?

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PROBLEM 1
A ball bearing is to be used for a shaft running at
400 rpm. Radial load is 4000N and axial load of
4000N. The is to have 10000 hours life at 95%
reliability. Determine the dynamic capacity of it.
Take b=1.34, Fa/Co = 0.5

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POINTS TO REMEMBER

Rated life @ 90% reliability = 1 mr

Any bearing life for more reliability is lesser than L 90

For example, L91< L90

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PROCEDURE

Required Life: 10000 hours @ 95% reliability

Rated life @ 90% will be ?

Axial load / Radial load = ?

For Fa/Co value, e, X, Y = ?

Service factor (S) = ?

Equivalent Radial Load (P) = ?

Dynamic capacity (C) = ?

37

TERMS TO UNDERSTAND
90% survival

For 1 mr (L90), load = C

For other life (L), load = P

Survival probability (p)

For p= 0.9, life = L90

For any other probability, life = L

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AVERAGE LIFE

L90 life = 1/5 of median life

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PROBLEM 2

Deep groove ball bearing SKF 6207 carries a

combined load of 1800N radially and 1200N axially
at 1200 rpm. The outer ring rotates and the bearing
is subjected to moderate shock. Find the average
expected life of this bearing (in hours).

40

PROCEDURE

Find the bearing capacities from Data book

Fa/Co = ?, e= ?

Fa/Fr = ?, find X,Y

Select V & S

P, L

Average life

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BELTS AND PULLEYS

FLEXIBLE M/C ELEMENTS

Transmission of power over long distances

Simplified design & hence cost reduction

Elastic & quite long shock absorption, isolates

vibration

Life cannot be much more as rigid elements

43

BELT TYPES

Flat belt

V- belt

Round belt

Timing belt

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ADVANTAGES OF BELT DRIVES

No lubrication is required / desired

Minimal maintenance (Infrequent)

Smooth operation

Pulleys (sheaves) are less costlier than chain

sprockets, little wear over long time

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DRAWBACKS

Endless belts not suit for repair only replacement

Slippage can occur

Belt & sheaves wear reduces belt tension

Adverse service environment affects belt

Length cannot be adjusted

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DESIGN CONSIDERATION

Power to be transmitted

Belt material

Speed of driver & driven pulleys

Diameter of pulleys

Centre distance

Space & service conditions

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BELT MATERIAL

Leather : stiff, suits for dry condn. < 45C

Cotton & canvas : fabrics bond with synthetic resins

Rubber : synthetic / vulcanized, moisture resist

Nylon core: suits for high speed, shock loads

Balatta : leather or fabric plies are bonded together

using balatta gum. Operating under 40C
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TENSION FORCES

Reason for tension force ?

When the driver starts, tension varies between tight

and slack sides

Belt mass contributes to any force?

If it so, what is it effect?

For economy, belt speed (v) = 25 30 m/s

For long life & , v = 15-20 m/s

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V -BELTS

Tension force remains same as flat belts

Wedging action changes the normal component

force.

Friction force changes

For the same belt tension, torque capacity is 3 fold

times more than flat belt/flat pulley drives
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ADVANTAGES OF V-BELTS

Can be employed for small distances

C(v-belt) = 0.55(D+d) +T
C(flat) = 2(D+d)

Reliability of the drive in any position

Very smooth in operation

High velocity ratios

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DIS- ADVANTAGES

High bending stresses, not so durable

Cannot be used for long distances as excessive

shocks affect its life

The pulley design is skillful, since the angle should

be taken care

Design is complex

Elastic creep is more than flat belt

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ENERGY LOSS

Belt travels b/w straight and curved sections

Tension forces fluctuates

Internal friction develops energy loss upto 2 %

Due to slip and creep , the efficiency reduces

overall = 95 -96 %
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1)

An open flat belt drive connects two parallel shafts

1.2 m apart. The driving and driven shafts are
rotating at 350 rpm, 140 rpm respectively. The
driven pulley is 400mm diameter. Power to be
transmitted is 1.1 kW. Design the flat belt drive.

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SOLUTION STEPS

1. Pulley diameters:

Driven - 400mm
Driver (400/350)*140 = 160mm

2. Design power (kW):

Rated kW = 1.1

Load correction factor = 1.2 (assuming steady load)

Arc of contact = 180 ((400-160)/1200)*60

= 168
Arc of contact factor (for 168) = 1.04 (approx.)

Small pulley factor = 0.75 (driver pulley is small and it is

above 100 & below 450)

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CONTD.

Design power = (1.1*1.2 )/ (1.04*0.75) = 1.69 kW

3. Belt selection: HI-SPEED duck belt is selected.

Belt capacity = 0.023kW/mm/ply

Rated velocity = *D*N/60

=(*160*350)/(60*1000)
= 2.9 m/s
4. Load rating @ rated velocity = 0.023 * 2.9 /10

= 0.00667 kW/mm/ply
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CONTD.
No. of plies:

5. Belt width:

For 160 mm dia, 2.9m/s velocity, the no of plies can be

assumed to be 4. (small pulley diameter - table)
= design power/ (load rating * no. of plies)
= 1.69 / (0.00667 * 4)
= 63.34mm
For 4 ply belt, the standard width is given as 76mm.

6. belt length:

L = 2C + *(D+d)/2+ (D-d)2/4C
= 3300mm

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CONTD.

7. Pulley width:

= belt width + 13mm

= 76 + 13= 89 mm
Recommended pulley width = 90 mm

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DESIGN PROCEDURE FOR V-BELT DRIVE

Design a V-belt drive and calculate the actual belt

tensions and average stress for the following data.
pulley diameters = 500mm, 150mm
Centre distance = 925mm
angular speed of pulleys = 300rpm, 1000rpm.
power to be transmitted = 7.5kW

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SOLUTION STEPS

1. belt section

2. pulley diameters

Cross section is selected based on power capacity &

pulley pitch diameter
B-section suits for this application

( Given )

3. Nominal pitch length:

L = 2C + *(D+d)/2+ (D-d)2/4C
= 2903mm
Select the nominal inside length 2845mm (since the
nearest standard value of nominal pitch length, 2888mm
is close to the obtained value)

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CONTD.

4. modification factors

correction factor for length, Fc = 1.05

Service factor, Fa= 1.3
(Assumed: light duty, over 16 hrs continuous service,
type II machine)
Arc of contact = 157.3

Arc of contact factor, Fd = 0.95 (approx.)

5. Maximum power capacity

B-section:
dp = 150 mm
Fb= 1.14 (for D/d = 3.3)
S = *D*N/60 = 7.85 m/s,
kW = 2.759

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CONTD.

6. No. of belts

= (P*Fa)/ (kW*Fc*Fd)
= 3.54 4

7. stress calculation

(T1 mV2) / ( T2 mV2) = e / sin(/2)

Lap angle = 157.3 = 2.74 radians
Friction coefficient = 0.3 (assumed )
= 40
m= 0.189 kg/m
Equation (1)
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CONTD.

Power transmitted by a belt:

(7.5*1000) / 4 = (T1-T2)*V
V= 7.85 m/s
Equation (2)

Find T1: (Max. tension)

274.5N

C/s area for B belt :

140mm2

Stress induced :
2Mpa (Approx.)

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RESULT
Belt c/s
Nominal inside length
Maximum power capacity
No. of belts
Max. tension force
C/s area
Stress induced

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CHAIN

DRIVES

CHAIN ELEMENTS
pitch
Link plate

width

Roller
Pin
66

67

FEATURES

No slip and creep

Smaller in size

Ability to drive many sprockets from a single power

source

Longer life than belts

Transmission efficiency is 98%

68

DISADVANTAGES

Regular wear changes the pitch

Periodic maintenance needed

Noise in operation

Non-uniform rotation of driven sprocket due to

chordal action

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CHAIN & SPROCKET

70

ANGLE OF ARTICULATION

The link swings for a small angle, /2

Its a fn of N.

It causes impact & wear

It should be minimum

71

CHORDAL SPEED VARIATION

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CHAIN CHORDAL ACTION

Equivalent mechanism for belt pulley system ?
Sprocket is like a pulsating pulley
The Instantaneous center varies cyclically

73

DESIGN PROCEDURE

Select : preferred transmission ration

Select: no. of teeth on pinion sprocket (z1)

Find: no. of teeth on wheel (z2 = i*z1)

Find: pitch (from centre distance)

Determine: total load on the driving side

Tangential force due to power transmission

Centrifugal tension force
Tension due to sagging of the chain link

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CONTD.

Fix the service factor (ks):

Nature of loads
Centre distance regulation
How the centre distance is proportional to pitch?
Sprocket positions (with horizontal)
Lubrication types
Period of operation

Calculate: design load

Check: bearing stress in the roller

Pitch circle diameter & sprocket outside diameter

75

PROBLEM 1

Design a chain drive to run a compressor from a

11kW electric motor at 970rpm, while the
compressor speed is 330rpm. The compressor
operates 16 hrs/ day. The approximate centre
distance is 500mm. Chain tension is adjustable.

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