Bearings Design Journal Bearing

29/09/2015

Contents Outline...
Bearings
Classifications
Bearing Selection
Lubrication and Viscosity
Basic Terminology
Viscosity and its units
Lubrications and Friction
Lubrication Regimes
Hydrodynamic Bearings
Performance of Hydrodynamic Bearings

29/09/2015

Contents Outline...
Hydrodynamic Effect
Pressure development in JB
Expression for film thickness (h)
Petroffs Equation
The Sommerfeld Number
Design Consideration
Angular Speed
Trumplers Criterion
Temperature
Raimondi and Boyd Charts
Problems and References
29/09/2015

Bearing Introduction
Bearing : Two parts moving relative to each other
constitutes a bearing. Sliding, rolling or both
The two parts are always separated, either by lubricant
or rolling elements like steel balls
Friction effects are integral while designing bearings
Study of wear and friction?

29/09/2015

Bearings Introduction ..
Usage:
To reduce friction where shafts, gears or wheels are used.
To provide high load tolerance
Applications:
Transportation including cars, trucks, heavy trucks, helicopters,
airplanes and trains.
Industries including mills, mining, oil and gas extraction and
production, gear drives, health and positioning control, wind
mills and food processing.

29/09/2015

Bearing Configuration

29/09/2015

Bearing Configuration
Journal Bearing

Provides radial location for a shaft rotating carries radial

load

Thrust Bearing

Provides axial location for a shaft rotating carries axial load

Slider Pad Bearing

Provides a load perpendicular to a continuous plane surface

along which the pad moves (usually in reciprocating motion)

29/09/2015

Bearings Types (according to

operating Mechanisms)
Rolling Element Bearings
Hydrodynamic Bearing (Fluid Film Bearings) Self Acting
Hydrostatic Bearing (externally pressurised)
Oil Impregnated (porous metal)
The mating surfaces are partially separated by an oil film
supplied from a reservoir of oil within the pores of the
sintered metal bearing.
Dry Rubbing

29/09/2015

Bearing Types (Operating Mechanisms)

29/09/2015

Journal Bearing in the shaft

arrangement

29/09/2015

Bearing Types (Mostly used)

29/09/2015

Selection of Bearing Types

29/09/2015

Bearing Selection Chart

29/09/2015

Types of Lubricant - Physical

Liquid
Typical lubricants are liquid/fluids
Mineral oil or synthetic oils

Solid
Graphite, MoS2

Semi solid
Greases

Gases
Atomised 2 stroke oils

Typical lubricants - Application

Engine oils
Gear Oils
Turbine Oils
Hydraulic Oils
Metal working oils
Cutting oils
Forming Oils

Rust preventives
Heat Treatment Oil
Refrigerating Oils

Lubricant - Components
Base Oils
Mineral by-products of crude oil refining process.
Base oils are polymerized or synthesized further and called
synthetic

Additives
Natural
Synthetic

Function of a lubricant
Lubricate - Reduce friction
Cooling - Heat transfer
Cleaning - Detergency
Noise pollution - dampening
Sealing prevent leakage
Protection prevent wear

Properties of lubricants
Dynamic viscosity
Kinematic viscosity
Viscosity index
Pour Point
Flash Point
Total Base Number (TBN)

Dynamic viscosity
u
=
y
The unit of dynamic viscosity is Ns/m2
In practice, centi poise use.

1P = 100cP = 0.1Pas

Kinematic viscosity

The unit of kinematic viscosity is m2/s

In practice, centi stoke use.
1cS = 1 mm2/s

Effects of temperature
The viscosity
temperature.

of

liquids

decreases

with

increase

the

The viscosity of gases increases with the increase the

temperature.

Viscosity Temperature Effect

Major specifying organizations

SAE Society of Automotive Engineers (USA)
API - American Petroleum Institute
US Military Specs US - MIL 2104 CCMC European Specification
ISO International Standard Organization ISO 3348
NLGI National Lubricating Grease Institute

Lubrication with SAE standard

based on Temperature

29/09/2015

SAE viscosity grades for engine oils

Designated
With corresponding viscosity
For high temperature application
Warmer areas/regions

SAE 20
SAE 30
SAE 40
SAE 10
SAE 50
SAE 60

SAE viscosity grades for engine oils

Designated
With corresponding viscosity
For low temperature application
Colder areas/regions

SAE 0 W
SAE 5 W
SAE 10 W
SAE 15 W
SAE 20 W
SAE 25 W

SAE viscosity grades for Mono

grades - Engine Oils
Mono grades are designated with single SAE number
SAE 10, 20, 30, 40, 50
SAE 5W,10W, 15W,20W,25W
Can be used either in summer season or in winter
seasons.
Gradual shift to multi grades.
Shift also due to lower oil consumption by multi grades
Available as Engine oil and Gear Oils

SAE viscosity grades for Multi

grades - Engine Oils
Multi grades are designated with two SAE number
Widely in use today
SAE 10w/30, 15w/30, 25w/50
SAE 5W/30, 20W/40
Suitable for use in winter and summer months or
seasons
Available in Engine oils & Gear oil

Petroffs Equation
The first explanation of bearing friction was given by
Petroff in 1883
It defines, groups of dimensionless parameters with
coefficient of friction
Assumptions :
bearing shaft is in concentric
It carries a small load
The clearance space is fully filled with oil
Leakages are negligible
29/09/2015

Journal Bearing Geometry

Bearing

bearing
journal

e
C

Rf

O
C

journal

No lubrication present

lubricant

Hydrodynamic load support

29/09/2015

Journal Bearing Nomenclature

C = centre of the journal
O = the centre of the bearing
W = unidirectional load of the journal (N)
= angular velocity of the journal (rad/s)
Rf = contact force (N)
N = normal contact force (N)
F = frictional force (N)
= coefficient of friction
h = film thickness (m)
= angular position from the position of max film thickness
29/09/2015

Performance parameters
Eccentricity (e) : the distance between the centres of the
bearing and journal (OC).
Radial Clearance (c) : difference in radii between the
bearing and journal
Eccentricity ratio () : the ratio between the eccentricity
and the radial clearance.
Minimum film thickness (hmin) : difference between the
radial clearance and eccentricity.
Attitude angle () : the angle between the load W and the
line of centres which lie both the maximum and minimum
film thickness

29/09/2015

Petroffs Equation Derivation

Please refer class lecture notes

29/09/2015

Lubrication Regimes (Stribeck

Curve)
Boundary
Lubrication

Contact between
journal and bearing

Mixed-film Lubrication
Intermittent contact

Hydrodynamic Lubrication
Journal rides on a fluid
film. Film is created by the
motion of the journal.

Mixed-film
Lubrication

Hydrodynamic
Lubrication

Coefficient of Friction

Boundary Lubrication

Bearing Parameter

Bearing Parameter

dynamic viscosity
rotational speed,

p pressure (force/projected area),

Lubrication Regimes

29/09/2015

Lubrication Regimes

Figure: Film conditions required for lubrication. (a) Fluid film lubrication surfaces separated by bulk lubricant film; (b) partial lubrication - both bulk lubricant
and boundary film play a role; (c) boundary lubrication - performance depends
essentially on boundary film.

Velocity Profile in Parallel surfaces

Velocity of top plate = 0
Direction of motion
of the bottom plate
y

Bottom layer of fluid moves with

same velocity as the plate
Shear force F
Lubricant

Velocity of bottom plate = U

A is area of the plate

There is no pressure buildup in the fluid due to relative motion

Pressure remains constant throughout influenced only by the load factor

The surfaces are move towards each other due to increase in load
29/09/2015

Velocity Profile in Converging

Wedge
Top Surface

Oil wedge

Direction of motion of the oil Wedge

Bottom surface

Surfaces are inclined to each other thereby compressing the fluid as it flows.

This leads to a pressure buildup that tends to force the surfaces apart

Larger loads can be carried

29/09/2015

Hydrodynamic Bearing Lubrication

Lift Force
Normal
Force

Top Surface

Drag Force
Oil wedge

Bottom surface
The hydrodynamic effect generates a hydrodynamic pressure in the fluid that result in
load carrying capacity, i.e. the fluid film has sufficient pressure to carry the external load
on the bearing.
29/09/2015

Reynolds Equation in One Dimension

Pmax

hi

Oil wedge

ho
U

U
B

29/09/2015

Introduction of Journal Bearing

A journal bearing, in its simplest form is a cylindrical bushing made of a

suitable material and containing properly machined inside and outside
diameters. The journal is usually the part of a shaft or pins that rotates inside
the bearing.

It is simply a block of cast iron with a hole for the shaft providing running fit.
An oil hole is drilled at the top for lubrication

The main advantages of this type of bearing are

It handle high load and velocities because metal to metal contact is minimal due to
the oil film.

The journal bearing is remarkably durable and long lasting

The damping effect of the oil film, journal bearing help make engines quiet and
smooth running.

29/09/2015

Journal bearing- process at

startup
Shaft/journal

e = eccentricity

Bearing
Stationary
journal

Instant of starting (tends to While running (slips due to loss

climb up the bearing)
of traction and settles eccentric to
bearing)

Because of the eccentricity, the wedge is maintained

(lack of concentricity)
29/09/2015

Hydrodynamic theory- journal

bearings
Shaft/journal

Top Surface

Bearing
Bottom surface

Oil wedge forms between shaft/journal and bearing due to them not being
concentric
29/09/2015

Theory of Hydrodynamic Bearings

Velocity Profile in Parallel Plates
Velocity Profile in Converging Wedge
Reynolds Equation in 1-Dimension
Reynolds Equation in 2- Dimensions
Simplifications of Reynolds Equation
Infinitely long bearing
Infinitely short bearing
Different shape of converging-diverging wedge

29/09/2015

Reynolds 1D equation continue..

Where,
h = fluid film thickness at any point in x-direction
h = fluid film thickness at maximum pressure condition
hi = fluid film thickness at entry
ho = fluid film thickness at exit
qx = fluid volume flow rate per unit width in x direction
U = velocity of bottom surface
Top surface velocity is zero
Entrainment velocity =
29/09/2015

U +0
=U /2
2

Reynolds 1D equation continue..

The flow rate per unit width

L3
L2
qx =
=
T
LT

The first term = Uh/2

The 2nd term is modifier, f(p), which depends on dp/dx, viscosity and film thickness h

qx =

Uh
f ( p)
2
a

dp
b
c
f ( p) =
( ) (L )
dx
To satisfy the units, a = +1, b = -1 and c = 3

29/09/2015

dp 1
f ( p ) = h3
dx

Reynolds 1D equation continue..

Thus, the new equation

Uh
h3 dp
qx =
k

2
dx

Where, k proportionality constant

The boundary conditions is, at some point, (dp/dx) = 0 and at the this point h will be h

qx =

Uh
2

dp U h h
3
=
dx
2
k

h

Where, k = 1/12 from experimental value

hh
dp
= 6U 3
dx
h
This is called as One Dimensional Reynolds Equation
29/09/2015

Reynolds Equation in Two Dimension

Assumptions:
1. The flow is laminar, since Re is low
2. The fluid lubricant is continuous, Newtonian and incompressible.
3. The fluid adheres to the solid surface at the boundary and there is no
slip at the boundary.
4. The fluid viscosity is constant.
5. The velocity component, v, across the thin film (y direction) is
negligible than other two velocity components in x and z direction.
6. The pressure, p, across the film in axial direction is constant.
7. The gravity and inertia forces are negligible.
29/09/2015

Reynolds 2D equation continue..

z
w2

qy +
qx

q y

x
u
v

qy

dy
A
29/09/2015

.dy

dx

w1

q x
.dx
qx +
x

Reynolds 2D equation continue..

Where,
h = fluid film thickness
x y = cross section of an incremental column
qx = fluid volume flow rate per unit width in x direction
qy = fluid volume flow rate per unit width in y direction
u,v, w = velocity components in x, y and z directions respectively.
A and B = rigid surfaces
A surface has u and v velocity components with w vertical velocity
component
B Surface has no translation rotation but has w vertical velocity
component
29/09/2015

Continuity of flow of a column

In x-direction, the volume flow rate per unit width is =

qx +

Where,
the rate of change of flow in the x direction = q x
x

The actual flow out is =

q x

.dx dy
qx +
x

In y-direction, the actual flow out is =

29/09/2015

q y

q y +
.dy dx
y

q x
.dx
x

Continuity of flow of a column

The volume of the column changes rate = ( w1 w2 ) dxdy
The total volume flow into the column

q x dy + q y dx + w1dxdy
The total volume flow out from the column

q y

q x

.dx dy + q y +
.dy dx + w2 dxdy
qx +
x
y

29/09/2015

Continuity of flow of a column

By equation flow in and out,

q x q y
+
+ (w2 w1 ) = 0
x
y

29/09/2015

An Element of Lubricant in the Film

29/09/2015

Equilibrium of an Element
The derivation and theory will be discussed in the lecture.
The relationship between volumetric flow rate and pressure gradients

Uh
h 3 p
qx =

2
12 x
Vh
h 3 p
qy =

2
12 y
29/09/2015

Full Reynolds Equation

The Reynolds equation,

h 3 p h 3 p
= 6 Uh + Vh + 2(w2 w1 )

+
y
x x y y

x
Since, the viscosity is constant in hydrodynamic lubrication theory,

3 p 3 p
h
h
= 6 U
+V
+ 2(w2 w1 )
h
+
x x y y
y
x

29/09/2015

Full Reynolds Equation continue...

In RHS, the first term two terms, are related to wedge action,
which creating the hydrodynamic pressure in the contact surfaces.

In RHS, the third term, W2-W1 is related to the rate of the height of
the fluid column changes. It could be written as dh/dt and this is
called as Squeeze film action.
When the bearing is running at steady state, squeeze film becomes
zero. But in real time, it is not steady state. Thus, squeeze film
neither zero or negligible. But it is small, when compared with the
contribution made to hydrodynamic pressure form the convergent
wedge action.
29/09/2015

Simplification of Reynolds Equation

Using full two dimensional form Reynolds Equation, it is difficult
to get general analytic solution. Thus, the entrainment velocity (V)
in y-direction is considered as zero. Also the squeeze film term
treated to zero. The simple form of Reynolds Equation in two
dimension,

3 p 3 p
h
h
= 6U
h
+
x x y y
x

29/09/2015

Infinitely long bearing

If the bearing is long in y-direction (infinite length), thus there is no
axial flow or pressure gradient. Then the simples form of Reynolds
Equation

3 p
h
h
= 6U
x x
x

dp
hh
= 6U
dx
h3
Where, h is the value of film thickness at which the pressure
gradient becomes zero.
In real bearings, for infinitely long, their longer dimension (L) is
at least 4 times bigger than their short dimension (Diameter, D).
29/09/2015

Performance Characteristics of
Hydrodynamic Bearings

29/09/2015

Journal Bearing Geometry

Bearing

bearing
journal

C
C

F
N

journal

No lubrication present

lubricant

Hydrodynamic load support

29/09/2015

Journal Bearing Nomenclature

C = centre of the journal
O = the centre of the bearing
W = unidirectional load of the journal (N)
= angular velocity of the journal (rad/s)
R = contact force (N)
N = normal contact force (N)
F = frictional force (N)
= coefficient of friction
h = film thickness (m)
= angular position from the position of max film thickness
29/09/2015

Performance parameters
Eccentricity (e) : the distance between the centres of the
bearing and journal (OC).
Radial Clearance (c) : difference in radii between the
bearing and journal
Eccentricity ratio () : the ration between the eccentricity
and the radial clearance.
Minimum film thickness (hmin) : difference between the
radial clearance and eccentricity.
Attitude angle () : the angle between the load W and the
line of centres which lie both the maximum and minimum
film thickness

29/09/2015

Performance parameters continue..

Bearing

e
c

c = Rb R

Where, Rb= radius of bearing

and R = radius of journal

0ec

journal
lubricant

29/09/2015

The radial clearance is

represented by c which is
in the order of 1/1000 of
the journal diameter.

Performance parameters continue...

0 1

If = 0, then there is no load, if = 1, then the shaft

touches the bearing surface under externally large loads.
The gap (h) between the solid surfaces, will be related
to circumferential position
h = c + e cos = c (1 + cos )

The minimum and maximum gap between the solid

surfaces,
hmin = c e = c (1 )
hmax = c + e = c (1 + )
29/09/2015

Journal Bearing Nomenclature

is equal to 2 for a
full bearing
If is less than 2, it is
known as a partial
bearing.
We will only be
considering the full
bearing case.

29/09/2015

Infinitely short bearing

Infinitely short or narrow bearing means, the length dimension (L)
in the y-direction is very much less than the dimension D.
L
< 0.25
D
D
L

p
p
>>
L
D

29/09/2015

p
p
>>
y
x

Infinitely short bearing continue...

h
3 p
h
= 6U
x
y y
h film thickness is function of x direction and not function of y

h
d2p
x
=

U
6
dy 2
h3
This famous equation is known as Ocvirks equation

29/09/2015

Infinitely short bearing continue...

dp
= 6U
dy

p = 3U

h
h

h
h

x y + C
1
3

x y 2 + C y + C
2
1
3

Pressure must be zero at either edge of the bearing, when y=

L/2, also dp/dy = 0 when y = 0. Thus C1 =0 and
C2 = 3U
p = 3U
29/09/2015

2
x L
h3 4

L
2
x
y

h
4

Short Journal Bearing Solution

The Reynolds equation for infinitely short bearing

p = 3U

L
2
x y

h
4

For journal bearings, x = R and dx=Rd and

h = c (1 + cos )
dh
c sin
=

dx
R

29/09/2015

Short Journal Bearing Solution

continue.....
L2
3U sin
2

y
p=
2
Rc (1 + cos ) 4

In full Sommerfeld conditions, the pressure curve is anti-symmetrical

about , as sin and cos is symmetrical about . Thus, axial
pressure distribution is parabolic.
At which angle the maximum pressure occur? m=?
To find m dp/d =0.
m
.
29/09/2015

1 1 + 24 2
= cos

Short Journal Bearing Pressure

Distribution

29/09/2015

Design Considerations
Controlled Variables : (Designer may control these)

Viscosity
Speed
Loads
Bearing Dimensions

Dependent Variables :(Designer cant control directly )

Temperature rise
Friction coefficient
Minimum film thickness
Volume flow rate

29/09/2015

Significant Angular Speed

The significant angular speed (N in rps) to use in
Sommerfeld Number,

N = N j + Nb 2N f

29/09/2015

Problem
Q1. An electrical generator rotor weighs 600,000 N and
rotates at 3600 rpm. It is supported by two journal bearings.
The journal diameter is 400 mm and the oil used is light SAE
30 oil. The oil filter allows particles of size 60m and the
peak surface roughness are 5m. Design the bearings. The
sump temperature is 20C.

29/09/2015

Other Design Criterion

Loads
Starting Load
Running Load
Starting Load

Wst
2.068MPa
LD
Running Load
Use a factor of at least 2
29/09/2015

hmin/C Vs (eccentricity ratio)

29/09/2015

Viscosity Chart
Vs Temp

29/09/2015

Temperature Effect
The average temperature is that the inlet and temperature
rise (T) from the inlet to the outlet of the lubricant

Tav

29/09/2015

T
= Ti +
2

Heat Loss

29/09/2015

29/09/2015

Temp Rise Equation

29/09/2015

Raimondi and Boyd Charts

29/09/2015

hmin film thickness position ()

29/09/2015

CoF Vs Sommerfeld Number

29/09/2015

Lubricant Flow Variable

29/09/2015

Flow Ratios

29/09/2015

Max Pressure Ratio

29/09/2015

Terminating Position

29/09/2015

Other L/D ratios

y=
1

8
1

1
12
14

12
1 4 1
3

1 4 1 +
1

24

+
1

1
4

Where,
y is the desired variable within the interval > L/D > and
y, y1, y1 and y1/4 are the variables corresponding to L/D
ratios of , 1, , and , respectively.
29/09/2015

Tutorials 3: Bearing Problems

Q1. A journal bearing has a shaft journal diameter of 75
mm, with a unilateral tolerance of -0.025 mm. The
bushing bore has a diameter of 75.125 mm with a
unilateral tolerance of 0.1 mm. The bushing bore is 37.5
mm in length and the load is 3.5 kN. The journal rotates
at 900 rpm. For SAE 40 lubricant, find the minimum film
thickness, the coefficient of friction and the maximum
film pressure for an operating temperature of 60 C for
the minimum clearance assembly

29/09/2015

Tutorials 3: Bearing Problems

Q2. A 32 32 mm sleeve bearing uses a grade 20 lubricant. The axial
groove sump has a steady state temperature of 45 C. The shaft journal
has a diameter of 31.75 mm with a unilateral tolerance of -0.025 mm.
The bushing bore has a diameter of 31.85mm with a unilateral tolerance
of 0.025mm. The journal speed is 1120 rev/min and the radial load is 2.5
kN. Estimat
a)The magnitude and location of the minimum film thickness
b)The eccentricity
c)The coefficient of friction
d)The power loss rate
e)Both the total and side oil-flow rates
f)The maximum oil-film pressure and its angular location
g)The terminating position of the oil film
h)The29/09/2015
average temperature of the side flow

Tutorials 3: Bearing Problems

Q3. A full journal bearing has a shaft journal diameter of 25
mm with a unilateral tolerance of -0.03 mm. The bushing
bore has a diameter of 25.04 mm with a unilateral tolerance
of 0.03 mm. The L/D ratio is unity. The bushing load is
1.25 kN, and the journal rotates at 1200 rpm. Analyse the
minimum clearance assembly if the average viscosity is 50
mPa.s to find the minimum film thickness, the power loss
and the percentage of side flow.

29/09/2015

Vogelpohl Equation

= 1000 + 0.4 x

Where,
V = Linear velocity of Journal bearing in m/s

29/09/2015