  © Design for lifetime performance and reliability
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Advanced engineering design Lifetime performance and reliability This book contains 536 pages in full color and over 250 illustrations, 300 formulae, 100 case studies and design examples, 50 easy calculators and 50 photographs of machine element failures. 
About the book
Contents
Index
How to buy?Contents Edition 2009
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 About the book: |
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The first part of this book concerns the fundamentals of "Design for lifetime performance and reliability", including design procedures to estimate and improve machine reliability, failure analysis, fatigue strength, static and dynamic load rating of concentrated contacts, friction phenomena, wear mechanisms, machine lubrication and material selection. These subjects are applied to design cases of various dynamically loaded machine elements. The second part concerns "Design of high performance and high reliability applications", including the design of hydrodynamically lubricated bearings and sliders, dynamic sealing systems, hydrostatic bearings, pressurized air bearings, flexure based mechanisms and many other bearings in high tech systems and mechatronic devices. Although the designer using this book is expected to have a good background in mathematics, the objective is that the design tools illustrated by cases will be useful anyhow. What's new? Most chapters are updated and extended especially the chapters Reliability engineering, Fatigue failure - prediction and prevention, Friction phenomena (stick-slip, hysteresis, backlash) and the chapter air bearings. Furthermore a new chapter is added "Bearings in high tech systems" with special attention to high precision systems, overall system specification and error budgeting, uncertainty etc. This chapter clearly shows the essence of design for stiffness, typically for high precision applications. Why should I buy this book? Keep up to date with the challenging and innovative techniques in the area of improved machine lifetime performance and reliability. Understand the fundamentals and know how to manage friction, wear and fatigue phenomena, lifetime and precision. Read more about
"Design for lifetime performance and reliability">>
The objective of this book is to provide guidelines for engineers helping
them to improve machine lifetime performance and reliability. Many books are
written about machine design. Most of these are focused on selection and
computation of basic machine elements. Those calculations generally relate to
the strength and stiffness of machine elements. In practice, it appears that few
machine problems are caused by these issues thanks to the attention paid to
strength calculation. |
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Contents |
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Contents Chapter 1: Reliability engineering Chapter 2: Failure modes of machine elements Chapter 3: Fatigue failure prediction and prevention Chapter 4: Rolling contact phenomena Chapter 5: Friction phenomena in mechanical systems Chapter 6: Wear mechanisms Chapter 7: Material selection a systematic approach Chapter 8: Lubricant selection and lubrication management Chapter 9: Design of hydrodynamic bearings and sliders Chapter 10: Performance and selection of sealing systems Chapter 11: Design of hydrostatic bearings Chapter 12: Design of aerostatic bearings Chapter 13: Design of flexure based mechanisms Chapter 14: Bearings in high tech systems |
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ADVANCED ENGINEERING DESIGN LIFETIME PERFORMANCE AND RELIABILITY  Chapter
1: Reliability engineering... 11.1 DESIGN FOR LIFETIME PERFORMANCE AND RELIABILITY 1 1.1.1 Introduction 2 1.1.2 History 5 1.1.3 Trends in mechanical engineering design 7 1.1.4 Innovative solutions 9 1.2 RELIABILITY ENGINEERING 10 1.2.1 Component reliability 10 1.2.2 System reliability 15 1.3 FAILURE ANALYSIS 18 1.3.1 Root Cause Failure analysis 18 1.3.2 Failure analysis techniques and procedure 19
2.1 HOW ROLLING BEARINGS FAIL 26 2.1.1 Load patterns and their interpretation 26 2.1.2 ISO 15243 failure mode classification 27 2.1.3 Bearing failures 28 2.2 HOW GEARS FAIL 34 2.2.1 ISO failure mode classification 34 2.2.2 Gear failures 34 2.3 HOW CAM FOLLOWER MECHANISMS FAIL 41 2.3.1 Failure mode classification 41 2.3.2 Cam follower failures 42 2.4 HOW RAIL / WHEEL SYSTEMS AND TRACTION DRIVES FAIL 44 2.4.1 Failure mode classification 44 2.4.2 Rail / wheel and traction drive failures 44 2.5 HOW JOURNAL BEARINGS FAIL 47 2.5.1 Failure mode classification 48 2.5.2 Journal bearing failures 48 2.6 HOW TRANSMISSION CHAINS FAIL 50 2.6.1 Failure mode classification 50 2.6.2 Chain drive failures 51 2.7 HOW KEY JOINTS FAIL 52 2.7.1 Failure mode classification 53 2.7.2 Key joint failures 53 2.8 HOW SCREW JOINTS FAIL 54 2.8.1 Failure mode classification 54 2.8.2 Screw joint failures 55
3.1 PREDICTION OF THE FATIGUE STRENGTH 58 3.1.1 Factors influencing the fatigue strength 58 3.1.2 Estimating the fatigue strength and endurance limit 64 3.2 DESIGN FOR RELIABILITY 68 3.2.1 Design of dynamically loaded drive shafts 68 3.2.2 Design of dynamically loaded bolted joints 74 3.2.3 Design of dynamically loaded welded structures 83
4.1 STATIC AND DYNAMIC LOAD RATING 92 4.1.1 Nominal point contact 92 4.1.2 Elliptic contact 99 4.1.3 Nominal line contact 101 4.1.4 Contact conformity 103 4.1.5 Geometrical stress concentrations 104 4.1.6 Rolling with traction 105 4.1.7 Permissible contact pressure 107 4.2 ROLLING RESISTANCE 109 4.2.1 Micro slip 109 4.2.2 Plastic deformation 110 4.2.3 Hysteresis losses 110 4.2.3 Spinning 112 4.2.4 Secondary friction losses 114 4.3 ELASTOHYDRODYNAMIC LUBRICATION 116 4.3.1 EHL-line contact 116 4.3.2 EHL-point contact 119 4.4 LOAD RATING OF MACHINE ELEMENTS 122 4.4.1 Static and dynamic load ratings of rolling bearings 122 4.3.3 Dynamic load rating of traction drive mechanisms 135
5.1 REAL CONTACT AREA 146 5.1.1 Surface Roughness 146 5.1.2 Ratio of real contact area and nominal contact area 150 5.2 FUNDAMENTALS OF FRICTION 153 5.2.1 Ploughing 153 5.2.2 Adhesion 155 5.3 CLASSICAL FRICTION LAWS 160 5.3.1 Effect of the nominal contact area 160 5.3.2 Effect of the normal load 160 5.3.3 Effect of sliding velocity 161 5.3.4 Effect of temperature 161 5.3.5 Effect of surface roughness 161 5.4 FRICTIONAL HEATING AND THERMAL FAILURE 162 5.4.1 Nominal contact temperature 163 5.4.2 Flash temperature 171 5.5 FRICTION PHENOMENA IN MECHANICAL SYSTEMS 173 5.5.1 Stick-slip in linear actuators 173 5.5.2 Hysteresis and virtual play 177 5.5.3 Joint Slippage phenomena 178 5.5.3 Side-slip to reduce effective friction 179 5.5.4 Jamming of linear guides 180 5.6 DEALING WITH FRICTION IN MECHANICAL SYSTEMS 181 5.6.1 Variable transmission belt drives 181 5.6.2 Metric thread, fasteners 184 5.6.3 Power screws 188 5.6.4 Interference fits 190 5.6.5 Slide bearings 195 5.7 MEASURING FRICTION 201 5.7.1 Manually 201 5.7.2 Motorised 203
6.1 TWO-BODY WEAR MECHANISMS 210 6.1.1 Adhesive wear 211 6.1.2 Abrasive wear 211 6.1.3 Corrosive wear 213 6.1.4 Surface fatigue 216 6.2 SINGLE-BODY WEAR MECHANISMS 217 6.2.1 Gas erosion 217 6.2.2 Liquid impingement erosion 217 6.2.3 Cavitation erosion 217 6.2.4 Particle erosion 217 6.3 CONTACT CONDITIONS 218 6.3.1 Contact conformity 218 6.3.2 Stationary contact 218 6.3.3 Degree of overlap 219 6.3.4 Contact temperature 219 6.4 WEAR RATE 220 6.4.1 Running-in 220 6.4.2 Calculation of wear rate 221 6.4.3 Classification of the specific wear rate 222 6.5 SELECTING OR CONSTRUCTING TEST APPARATUS 229 6.5.1 Pin-on-disc / Pin-on-ring 230 6.5.2 Pin-on-flat / ball-on-flat 231 6.5.3 Two disk 231 6.6 STANDARDS FOR MEASURING FRICTION AND WEAR 232 6.6.1 Specimen preparation 232 6.6.2 Experiment 233 6.6.3 Reporting 233 6.6.4 Reproducibility 233
7.1 MATERIALS FOR SLIDE SURFACES 238 7.1.1 Selection criteria for metals 238 7.1.2 Selection criteria for polymers 242 7.1.3 Selection criteria for technical ceramics 255 7.2 COATINGS AND SURFACE TREATMENTS 258 7.2.1 Where surface treatments are applied 258 7.2.2 Classification of surface treatments 259 7.2.3 Surface treatment techniques 260 7.3 MATERIAL SELECTION: A SYSTEMATIC APPROACH 267 7.3.1 System identification 267 7.3.2 Definition of material selection criteria 267 7.3.3 Pre-selection of materials 267 7.3.4 Experimental setup 268 7.3.5 Selection of the best candidate(s) 268
8.1 LUBRICATION REGIMES 274 8.1.1 Stribeck curve 275 8.1.2 Transition diagram 277 8.2 LUBRICANTS 278 8.2.1 Physical properties 278 8.2.2 Additives 284 8.2.3 Oil supplements 286 8.2.4 Trends in engine and industrial lubrication 288 8.3 TYPES OF LUBRICANTS AND LUBRICANT SELECTION 289 8.3.1 Base oils 289 8.3.2 Biolubricants 290 8.3.3 Food grade lubricants 292 8.3.4 Lubricants for thermoplastics, thermosets and elastomers 292 8.3.5 Greases 293 8.3.6 Solid lubricants 296 8.3.7 Lubricant selections for specific applications 299 8.4 LUBRICATION MANAGEMENT 301 8.4.1 Grease versus oil lubrication 301 8.4.2 Oil lubrication systems 301 8.4.3 Engine lubrication system 302 8.5 PROACTIVE MAINTENANCE AND OIL ANALYSIS 303 8.5.1 Maintenance engineering 303 8.5.2 Proactive maintenance 304 8.5.3 Causes of lubricant deterioration and their prevention 305 8.5.4 Chemical and physical oil analysis 306 8.5.5 Wear particle analysis 307
9.1 HYDRODYNAMIC LUBRICATION 314 9.1.1 Reynolds equation 315 9.1.2 Effective surface velocity 319 9.1.3 Film thickness in journal bearings and concentrated contacts 321 9.1.4 Viscous shear 322 9.2 SLIDER BEARINGS 324 9.2.1 Converging wedge 324 9.2.2 Michell bearing 326 9.2.3 Rayleigh step bearing 329 9.2.4 Tapered land pad 332 9.2.5 Curved pad 334 9.3 PLAIN JOURNAL BEARINGS 335 9.3.1 Bearing performance and design 335 9.3.2 Design optimization load versus bearing clearance 343 9.3.3 Design optimization friction versus film thickness 345 9.3.4 Bearings in turbo machinery 346 9.4 VISCOUS DAMPING AND DYNAMIC RESPONSE 347 9.4.1 Dashpot 347 9.4.2 Band on flat 352 9.4.3 Circular disk on flat 354 9.4.4 Circular ring on flat 355 9.4.5 Cylinder on flat 355 9.4.6 Squeeze film dampers 356 9.4.7 Shock loaded journal bearings 358 9.4.8 Dynamically loaded slider bearings 360 9.4.9 Piston ring/liner film development 362 9.4.10 Dynamically loaded journal bearings 363
10.1 SEALING SYSTEMS 372 10.1.1 Classification 372 10.1.2 Operating limits 372 10.2 ROTARY SEALS 373 10.2.1 Lip seals, V-rings and O-rings 373 10.2.2 Mechanical face seals 375 10.2.3 Seal face patterns 379 10.2.4 Gap seals 380 10.2.5 Labyrinth seals 381 10.2.6 Magnetic fluid seals 382 10.2.7 Air barrier seals 383 10.3 RECIPROCATING SEALS 383 10.3.1 Reciprocating lip-seals in hydraulics 383 10.3.2 Reciprocating lip-seals in pneumatics 385 10.3.3 Piston guide rings 387 10.3.4 O-rings in reciprocating applications 389 10.3.5 Piston ring-seals in engines 391
11.1 BASIC METHODS OF OPERATION 396 11.2.1 Methods to obtain bearing stiffness 397 11.2.2 Advantages and limitations of pressurised fluid bearings 398 11.2 DESIGN OF HYDROSTATIC BEARINGS 399 11.2.1 Basic construction elements 399 11.2.2 Hydrostatic thrust bearings with shallow pocket 404 11.2.3 Hydrostatic thrust bearings with tapered film 405 11.2.4 Hydrostatic thrust bearings with capillary restrictor 405 11.2.5 Hydrostatic thrust bearings with orifice restrictor 410 11.2.6 Hydrostatic preloaded thrust bearings 413 11.2.7 Hydrostatic journal bearings with external restrictors 415 11.2.8 Hydrostatic journal bearings with shallow pockets 419
12.1 BASIC METHODS OF OPERATION 428 12.1.1 Methods to obtain bearing stiffness 429 12.1.2 Advantages and limitations of pressurised gas bearings 431 12.1.3 Structural considerations and kinematics 432 12.2 DESIGN OF E.P. AIR BEARINGS 435 12.2.1 Basic construction elements 435 12.2.2 Design of air bearings with orifice restrictor 439 12.2.3 Design of air bearings with a series annular orifice restrictors 441 12.2.4 Design of air bearings with a series simple orifice restrictors 442 12.2.5 Design of air bearings with partial porous surface 443 12.2.6 Design of shallow pocket air bearings 444 12.2.7 Design of partially grooved air bearings 445 12.2.8 Design of taper and taper-land air bearings 446 12.2.9 Design of journal bearings with porous ring restrictor 447 12.2.10 Design of journal bearings with two porous rings 449 12.2.11 Design of partially grooved journal bearings 450
13.1 BASIC DESIGN PRINCIPLES AND COMPONENTS 456 13.1.1 Design considerations 456 13.1.2 Basic construction elements 460 13.1.3 Dynamic load excitation response 462 13.1.4 Design of hole hinges 467 13.1.5 Micro actuators 469 13.2 DIVERSE APPLICATIONS 470 13.2.1 Flexure cross hinge 470 13.2.2 Piezo parallel guiding with integrated motion amplifier 471 13.2.3 Piezo nano precision XY-parallel mechanism 472 13.2.4 Flexible shaft couplings 473 13.2.5 Monolithic flexure plain bearing 473
14.1 SYSTEM DESIGN 476 14.1.1 Resolution, accuracy and repeatability 476 14.1.2 Error budgeting 477 14.1.3 Errors in translation and rotation 480 14.1.4 Overall system accuracy 482 14.2 ACTUATORS AND CONTROLLERS 482 14.2.1 Stepper motor versus servomotor 483 14.2.2 Rack & pinion versus Traction wheel drive 483 14.2.3 Ball screw versus lead screw 484 14.2.4 Ball screw versus linear motor 484 14.2.5 Iron core versus ironless linear motor 485 14.3 LINEAR GUIDE SYSTEMS 487 14.3.1 Dovetail slides versus rolling guides 487 14.3.2 Rolling guide versus E.P. bearings 488 14.3.3 Air bearings versus hydrostatic bearings 488 14.3.4 Air bearings versus active magnetic bearings 488 14.4 BEARINGS IN MECHATRONIC SYSTEMS 489 14.4.1 Plain journal bearings 489 14.4.2 Jewel bearings 491 14.4.3 High precision ball bearings 495 14.4.4 Spiral groove bearings 496 14.4.5 Magnetic fluid bearings 505 14.4.6 Hydrostatic bearings 505 14.4.7 E.P. Air bearings 506 14.4.8 Magnetic bearings 506 14.4.9 Foil air bearings 508 14.4.10 Hybrid bearings in high speed rotary applications 509
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Index
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A Abbé error 481 Abbott-Firestone curve 148 Abrasive wear 29, 211 Accuracy 476 Active magnetic bearings 488 Actuators 482 Additives 284 Adhesion 155 Adhesive wear 30, 211 Aerostatic bearings 427 Aerostatic instability 428 Aftermarket additives 286 Air barrier seals 383 Allowable stress number 128 Aluminium alloys 459 Aluminium-soap greases 294 Amontons-Coulomb law 5 Amorphous polymers 243 Angular contact ball bearings 112 Annular orifices 429 Anti-foam additives 286 Anti-friction coatings 298 Anti-oxidant 285 Anti-wear additives 284 Aquaplaning 274, 365 Archard’s equation 221 Assembly clearance 195 Attitude angle 335 Austenitic stainless steels 214 Average bearing pressure 195 B Babbitts 240 Backlash 177, 476, 479 Backup bearings 506, 507 Balance ratio 377 Ball screw 484 Ball-on-flat 231 Barus 283 Basic rating life 124 Bath lubrication 301 Bathtub failure 11 Bearing number 337 Bearing stiffness 335 Beauchamp Tower 5, 315 belt drives 181 Bending stiffness 461 Bernoulli 435 Bernoulli equation 400 Bingham-type 294 Biolubricants 290 Biomaterial 249 Bleeding 295 Blok 342 Bolt failure 74 bolt joint 185 Bolted assemblies 75 Bolzmann integrals 246 Boriding 261 Boron Nitride 297 Boundary Lubrication 274 Boundary lubrication additives 284 Brinell hardness 97 Brinelling 215 brittle materials 107 Bronzes 240 Buckling 466 burnishing 149 C Calcium-soap greases 294 Camshaft 42 Cantilever beams 464 Cantilever loading 481 Capillary restrictor 400, 435 Carburising 261 Case crushing 39 Cavitation 335 Cavitation algorithm 392 Cavitation erosion 217 CD-ROM drive 234 Ceramic ball bearings 257 Chain drive failures 51 Chemical and physical oil analysis 306 Chemical Vapour Deposition 263 Circulation lubrication 301 Cladding 263 Classic friction laws 160 Cleanliness 309 Closed pocket textures 392 Closed system 219 Cloud Point 279 Coatings 258 Cogging 485 Cold welding 211 Cold-welding 210 Compatibility 157 Compatibility: 385 Complex soap greases 293 Compliant mechanisms 456 Component reliability 10 Compounded oils 290 Compressibility 284, 319 Compression ring 391 Concentrated contacts 92 Condition monitoring 304 Cone-on-plate viscometer 310 Coning 376 Consistency 295 Contact angle 112 Contact conditions 218 Contact conformity 103, 218 contact mechanics 91 Contact temperature 219 Corrosion inhibitors 285 Corrosive wear 213 Couette film thickness 324 Couette flow 317 Couette flow film thickness 318 Coulombs friction laws 5 Couplings 473 Crack formation 215, 216 Creep response 245 Critical shear stress 107 Critical speed 495, 510 Cross spring hinge 458 Crystallinity 243 Cumulative damage 84 Current leakage 32 Curved pad 334 Cylinder liner 391 Cylinder Viscometer 280 D Damage analysis 20 Damping 174, 347 Dashpot 347 Data sheet 233 Deflection curve 460 Degree of overlap 219 Delamination 216 Demulsifiers 286 Design for Environment 9 Design For Reliability (DFA) 68 Detergents 285 Deterministic approach 14 Diamond Like Carbon coatings 264 Differential particle counting 309 Disk brake 204, 234 Dispersancy 306 Dispersants 285 Dovetail slides 487 Dropping point 295 Dynamic error budgeting 482 Dynamic load excitation response 462 Dynamic load rating 124 Dynamic response 347 Dynamic seals 371 Dynamic viscosity 280 d’Arcy law 435 E E.P. bearings 395 E.P. gas bearings 427 Eccentric piston 352 Eccentricity locus 335 Eccentricity ratio 321 Effective contact radius 103 Effective friction coefficient 181 Effective heat conduction length 168 Effective heat diffusion length 166 effective modulus of elasticity 92 effective radius 93 Effective surface velocity 319 EHL-line contact 116 EHL-point contact 119 Elastic recovery 156 Elastic shakedown 107 Elasto Hydrodynamic Lubrication 274 Electro-thermal actuators 469 Electroless nickel 262 Elliptic contact 99 Endurance limit 61, 64, 65 Engine friction losses 287 Engine lubrication system 302 Engine oils 279 Engineering ceramics 255 Engineering design 9 Engineering plastics 248, 249 Environmental design 9 Environmental Standards 290 EP additives 127 EP-additives 285 EPDM 385 Error budgeting 477, 482 Error mapping 482 Euler definition 319 Excessive voltage 31 F Fading 162 Failure analysis 19, 25 Failure Analysis (FA) 18 Failure distribution functions 11 Failure Mode Effect Analysis (FMEA) 16 False brinelling 31, 215 Fastener assembly methods 79 Fatigue 3 Fatigue breakage 40 Fatigue corrosion 61 Fatigue crack development 58 Fatigue failure 28 Fatigue life 108 Fatigue strength 63, 64, 108 Fatty oils 290 Fault Tree Analysis (FTA) 16 Ferrofluids 505 Fillet radius 70 Film thickness in journal bearings 321 Finishing techniques 149 Fire point 306 Fissures and cracks 39 Flake pitting 39 Flaking 210 Flash point 306 Flash temperature 171 Flexure hinges 456 Flexure mechanisms 455 Floating seal 390 Flow-restrictor 396 Fluorcarbon Rubber 385 Foil bearings 508 Food and Drug Administration 292 Food grade lubricants 292 Forced circulation lubrication 302 Fracture 33 Fretting corrosion 31, 191, 214 Fretting wear 215 Friction coefficients 189,239,241,251,264 Friction coefficients - polymers 252 friction laws 160 Friction modifiers 284 Frictional heating 162 Fuel economy benefit 282 G Galling 210, 211 Galvanic coatings 262 Gap seals 380 Gas bearings 427 Gas erosion 217 Gas seals 379 Gear design 132 Gear oils 299 Gears 128 General purpose oils 299 General purpose plastics 247 Generalised Kelvin model 247 Generalized Maxwell model 247 Glass transition temperature 243 Graphite 297 Grease characteristics 294 Grease lubrication 301 Greases 293 Grey staining 38 Grinding 210 Guide elements 384 H Half-omega whirl 336 Hard anodising 262 Hard chromium 262 Hard disks 234 Hard wearing 222 Hard-facing 263 Hardness conversion 99 Hardness scales and conversion 97 Hazard rate 11 Heathcote slip: 109 Herringbone pattern 501 Herschel-Bulkley model 294 Hertzian contact stresses 95 Hertzian contacts 92 High cycle fatigue HCF 61 High performance plastics 249 High pressure viscosity 283 High shear viscosity 281 Hole hinges 457 honing 149 HP/HVOF 262 hybrid ball bearing 139 Hybrid bearing systems 509 Hybrid bearings 398 Hydraulic fluids 300 Hydraulic oils 299 Hydropad seals 379 Hydrostatic bearings 395 Hysteresis 110, 177, 456, 476 Hysteresis error 478 I Impedance method 360 Impulse 355 Impulse force 353 Impulse method 360 Indents from debris 32 Induction hardening 260 Industrial lubrication 288 Infant mortality 11 Infinite fatigue life design 61 Inherent orifices 429 Inherent reliability 11 Initial pitting 38 Interference fits 127, 178, 190, 195 Internal clearance 126 Iron core linear motor 484 Ironless linear motor 485 J Jamming 180 Jewel bearings 491 Joint slippage 178 Joint stiffness factor 76 Journal bearings 335 K Kelvin model 245 Key joint failures 52 Key ways 71 Kingsbury 326 Kolsterising 262 L Labyrinth gas seals 381 Labyrinth seals 381 Lame’s equation 190 Lapping 149 Laser texturing 391 Lateral Traction 106 Lead babbitts 240 Lead screw 484 Leave springs 456 Leonardo Da Vinci 5 Life expectancy 13 Limiting shear stress 137 Limiting speed 125 Line contact 101 Linear motor 484 Liquid impingement erosion 217 Lithium-soap greases 293 Load patterns 26 Locating bearing 68 Locus 335 Lord Rayleigh 329 Low cycle fatigue LCF 61 Lubricant deterioration 305 Lubricant life additives 285 Lubricant selection 278, 289 Lubricant selections 299 Lubricant viscosity 278 Lubricants for thermoplastics 292 Lubrication management 301 Lubrication transitions 276 Lubricity 284 M Machine monitoring 304 Magnetic bearings 506 Magnetic fluid bearings 505 Magnetic fluid seals 382 Magnetic fluids 382 Magnetic levitation 486 Magnets 382 Maintenance engineering 303 Martensitic stainless steel 214 Material selection 237 Maximum Hertzian contact load 95 Maximum tightening torque 185 Maxwell model 246 Measuring friction 201 Mechanical face seals 375 Melting temperature 244 Metal Matrix Composites (MMCs) 241 Metallurgical compatibility 156 Michell bearing 326 Micro actuators 469 Micro elastohydrodynamic lubrication 392 Micro pitting 38 Micro slip 109 Micro welding 162 Micro-EHL 275 Micro-peening 263 Mineral oils 289 Miner’s rule 84 Misalignment 481 Mixed Lubrication 275 Mobility method 360 Moisture corrosion 30 Molybdenum Disulfide, MoS2 297 Moments of inertia 464 Monolithic flexure hinges 470 Mutual solubility 156
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N Naphthenic oils 289 Newtonian fluids 280 Nitriding 261 Nitrocarburising 261 Nitrotec process 261 NLGI consistency number 295 Nominal contact area 146 Nominal contact temperature 163 Non-Newtonian models 294 Non-repeatable runout 236 Non-stationary contact 219 Normal distribution 13 Normal failure distribution 13 Normalised impulse force 355 Notched flexure hinges 458 Nut 189 O O-rings 375, 387, 389 Ocvirck bearing 340 Oil analysis 304 Oil control ring 391 Oil lubrication 301 Oil lubrication systems 301 Oil monitoring 304 Oil supplements 286 Open system 219 Operating clearance 195 Operational clearance 126 Operational reliability 11 Organo-clay thickener 294 Orifice restrictor 400 Orifices 435 Osborne Reynolds 5, 315 Outgassing 249 Overload breakage 40 Oxidation 305, 307 Oxidative wear 210 Oxide layer 158 Oxidised abrasive 214 P Pack-aluminising 262 Pack-chromizing 261 Palmgren-Miner 6 Palmgren-Miner rule 84 Paraffinic oils 289 Partial porous surface 430 Particle counter device 309 Particle erosion 217 Peclet Number 166 Periodic load 348 Periodical maintenance 304 Petroleum 289 Phosphate esters 290 Physical Vapour Deposition 263 Piezoelectric actuators 469 Pin-on-disk 230 Pin-on-flat 231 Pin-on-ring 230 Piston rings 362, 391 Piston seals 384 Piston-cylinder lubrication 303 pitch point 130 Pitting 210 Plasma CVD 264 Plastic - plastic combinations 251 Plastic bearings 489 Plasticity index 150 Plate-shaped particles 216 Ploughing 153, 210 Pneumatic hammer 428 point contact 92 Poisseuille flow 317 Polishing wear 210 Polyalkylene glycols 290 Polyalphaolefins 290 Polyisobutylenes 290 Polyurea grease 294 Porous metal bearings 491 Porous surface 430, 435 Pour point 279 Power screws 184, 188 Predictive Maintenance Management 303 Preload a bolt 77, 186 Preloading 126 Pressure angle 126 Pressure feed lubrication 302 Pressure spikes and micro pitting 152 Pressure-viscosity dependency 283 Pressurised fluid bearings 398 Probabilistic approach 14 Probability Density Chart 10 Probability of failure 10 Progressive pitting 38 Prototype testing 229 PTFE 250, 298 PV-value 199 R R&O additives 285 Rack & pinion 483 Rail-wheel contact 367 Ratcheting 108 Rayleigh step 329 Real contact area 146 Reference speed 125 Reliability 11 Reliability Engineering 10 Reliability factor 124 Relieve cut 70 Repeatability 233, 476 Reporting 233 Reproducibility 233 Resolution 476 Retaining rings 70 Reynolds boundary condition 339 Reynolds Equation 318 Reynolds slip 109, 110 Rheological properties 294 Ringstone jewel bearings 494 Risk Priority Number 16 Rockwell hardness 98 Rod seals 384 Roelands 283 Rolling guidance systems 487 Rolling guide 140 Rolling resistance 109 Root Cause Analysis (RCA) 18 Root Cause Failure Analysis 18 Rotary lip seal 373 Roughness 146 Running accuracy 127 Running-in 220, 276 S S-N Diagram 61 SAE Viscosity Grades 279 Sassenfeld and Walther 315, 342 Scoring 210 Scratching 36, 210 Screw efficiency 189 Screw joint failures 54, 55 Screw spindle 189 Scuffing 210, 211 Sealing systems 372 Sealing washers 381 Seizure 210, 211 Self-locking 188 Self-lubricating composites 299 Self-lubricating plastics 250 Semi-crystalline plastics 243 Service temperature 243 Servomotor 483 shakedown 107 Shallow pocket bearing 404 Shear modulus 464 Shear strength 63 Shear stress criterion 107 Shore hardness 98 Shot-peening 263 Shotpeening 216 Side-slip 179 Single body wear 210, 217 Sintered metal bearings 490 Sintered metals 241 Slip equation 181 Slip front 178 Slippage 178 Slot feeding 429 Slumpability 295 Smearing 210 Solid lubricants 296 Solidification 284 Solidification pressure 137 Sommerfeld 315 Sommerfeld boundary condition 338 Spalling 39, 210, 216 Specific wear rate 221 Specimen preparation 232 Spiral groove bearings 496 Splash lubrication 301 Spring balance 201 Spring materials 459 Spring stiffness 465 Squeaking 106 Squealing 106 Squeeze film dampers 356 Stability 503 Stainless steels 214 Standard deviation 13 Standard Solid model 246 Standardised tests 229 Starved lubrication 362, 392 Static load rating 96, 122 Stationary contact 218 Stationary heat flow 164 Stepped shafts 69 Stepper motor resolution 477 Stick- and slip zone 109 Stick-slip 173, 177, 251 Stick€slip 479 strain recovery 246 Strain response 245 Stress concentration factor 59 Stress corrosion 61 Stress relaxation 246 Stress response 245 Stress-relaxation 246 Stribeck curve 120 Stribeck-curve 275 Subsurface fatigue 28 Subsurface initiated cracks 37, 45 Sulphurizing 261 Super-finishing 149 Surface durability 128, 132 Surface energy 156 Surface Fatigue 216 Surface hardening 260 Surface roughness 146 Surface texturing 391 Surface topography 392 Surface treatments 258 Surface-initiated fatigue 29 Synthetic esters 290 Synthetic oils 289 System reliability 15 T Tapered land pad 332 Technical ceramics 255 Test apparatus 230 Thermal expansion 480 Thermal micro actuators 469 Thermo-chemical wear 210 Thermoplastics 242 Thermosets 254 Thin-film approach 317 Thread lubricants 185 Thread shear 187 Three-body wear 210 Thrust washer 231 Tightening torque 184 Tilted plane 202 Tire width 205 Tooth bending strength 128, 134 Tooth breakage 40 Tooth end breakage 41 Torsional stress 82, 186 Total Acid Number (TAN) 307 Touchdown bearings 506 Tower 5 Traction drive mechanisms 136 Traction wheel drive 483 Transient heat flow 165 Transition diagram 277 Transmission torque 190 Trend monitoring 304 Trends in machine design 7 Tresca’s shear criterion 63, 95 Tresca’s yield criterion 107 Tribology 3 Tribometer 230 Tube expansion 367 Turbine oil 300 Two disk tribometer 231 Two roller tribometer 231 Two-body wear 210 U Ultimate tensile strength 63 Uncertainty 482 US Department of Agriculture 292 V V-block bearings 495 V-pivot jewel bearing 493 V-ring seals 375 Variable amplitude loading 84 Vegetable oils 289 Vibrating rotor 336, 339 Vibration 126, 173 Vickers hardness 98 Virtual play 177 Visco seals 497 Visco-elastic behaviour 245 Viscosity classification 279 Viscosity Index 282 Viscosity index improvers 284 Viscosity of gases 431 Viscosity-pressure coefficient 121 Viscous damping 347, 348 Viscous seal 382 Viscous shear 322 Viscous shearing 349 Von Mises equivalent stress 464 Von Mises failure criterion 107 von Mises yield criterion 63, 97, 107 W Water 291 Wave seals 374 Wear coefficient 221 Wear measurement 233 wear mechanisms 210 Wear mechanisms terminology 210 Wear particle analysis 307 Wear rate 220 Wedge effect 318 Weibull failure distribution 12 Welded structures 83 Whirl instability 336 Whirl modes 510 Windscreen wiper 393 Wipers 384 Wire springs 456 Wöhler 6 Wohler diagram 61 Work-hardening factor 132 Worm-gear oils 299 Wrap angle 182 XYZ Yield strength 63
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