Machine Design: Lifetime performance and reliability, Tribology

© Machine lifetime performance and reliability

Machine lifetime performance and reliability
ISBN 90 3700 208 0

This popular hard cover book contains 432 pages 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

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About the book:

Part A: The text of this book is divided into two parts. The first concerns “Dynamic Contact Phenomena” including static and dynamic load rating of Hertzian contacts, friction phenomena, wear mechanisms, machine lubrication, material selection and failure analysis. It is expected that this part belongs to the under graduate program of mechanical engineering.

Part B: The second part concerns “Full Film Lubrication” and includes the study of hydrodynamic lubricated bearings and sliders, squeeze film damping and dynamic response, dynamic sealing systems, EHL rolling and traction mechanisms, hydrostatic bearings and pressurised gas bearings. Although the designer using this part is expected to have a good background in mathematics, the objective is that the design tools illustrated by cases will be useful anyhow.

Contents

Part A: Dynamic contact phenomena

   Chapter 1: Machine lifetime performance and reliability...3
   Chapter 2: Static and dynamic load rating... 9
   Chapter 3: Friction phenomena in mechanical systems... 55
   Chapter 4: Wear mechanisms of machine elements...105
   Chapter 5: Machine lubrication and beyond ...133
   Chapter 6: Material selection a systematical approach ...173
   Chapter 7: Failure analysis ...213

Part B: Full film lubrication

   Chapter 8 : Introduction to full film lubrication ...239
   Chapter 9 : Hydrodynamic lubricated bearings and sliders ...253
   Chapter 10: Squeeze film damping and dynamic response ...287
   Chapter 11: Dynamic sealing systems ...309
   Chapter 12: EHL seals, mechanisms and forming processes.331
   Chapter 13: Hydrostatic bearings ...357
   Chapter 14: Aerostatic bearings ...389

Preface to the first edition III

Part A: Dynamic contact phenomena
NOMENCLATURE - PART A ...2

Chapter 1: Machine lifetime performance and reliability...3
1.1 MACHINE LIFETIME PERFORMANCE AND RELIABILITY ...4
1.1.1 Introduction ...4
1.1.2 History ...5
1.1.3 Trends in machine design ...7

Chapter 2: Static and dynamic load rating... 9
2.1 CONCENTRATED CONTACTS ...10
2.1.1 Nominal point contact ...10
2.1.2 Elliptic contact ...17
2.1.3 Nominal line contact ...19
2.1.4 Contact conformity ...21
2.1.5 Geometrical stress concentrations ...22
2.1.6 Rolling with traction forces ...23
2.1.7 Permissible contact pressure ...25
2.2 LOAD RATING OF MACHINE ELEMENTS ...27
2.2.1 Static and dynamic load ratings of roller bearings ...27
2.2.2 Surface-load rating of gears ...30
2.2.3 Traction drive mechanism ...37
2.2.4 Surface pressure in plain bearings ...38
2.3 REAL CONTACT AREA ...41
2.3.1 Surface Roughness ...42
2.3.2 Ratio of real contact area and nominal contact area ...46

Chapter 3: Friction phenomena in mechanical systems... 55
3.1 FUNDAMENTALS OF FRICTION ...56
3.1.1 Ploughing ...56
3.1.2 Adhesion 58
3.2 CLASSIC FRICTION LAWS ...63
3.2.1 Effect of the nominal contact area ...63
3.2.2 Effect of the normal load ...63
3.2.3 Effect of sliding velocity ...64
3.2.4 Effect of temperature ...64
3.2.5 Effect of surface roughness ...64
3.3 FRICTIONAL HEATING AND THERMAL FAILURE ...65
3.3.1 Nominal contact temperature ...66
3.3.2 Flash temperature ...74
3.4 FRICTION PHENOMENA IN MACHINE ELEMENTS ...76
3.4.1 Stick-slip in linear actuators ...76
3.4.2 Side-slip to reduce effective friction ...77
3.4.3 Jamming of linear guides ...78
3.4.4 Variable transmission belt drives ...79
3.4.5 Metric thread, fasteners ...82
3.4.6 Power screws ...87
3.4.7 Interference fits ...89
3.4.8 Deep groove roller bearings ...92
3.4.9 Roller guides ...95
3.4.10 Angular contact ball bearings ...95
3.4.11 Spherical thrust bearing ...96
3.5 MEASURING FRICTION ...99
3.5.1 Manually ...99
3.5.2 Motorised ...100

Chapter 4: Wear mechanisms of machine elements...105
4.1 TWO-BODY WEAR MECHANISMS ...106
4.1.1 Adhesive wear ...107
4.1.2 Abrasive wear ...107
4.1.3 Corrosive wear ...109
4.1.4 Surface fatigue ...111
4.2 SINGLE-BODY WEAR MECHANISMS ...113
4.2.1 Gas erosion ...113
4.2.2 Liquid impingement erosion ...113
4.2.3 Cavitation erosion ...113
4.2.4 Particle erosion ...113
4.3 CONTACT CONDITIONS ...114
4.3.1 Contact conformity ...114
4.3.2 Stationary contact ...114
4.3.3 Degree of overlap ...115
4.3.4 Contact temperature ...115
4.4 WEAR RATE ...116
4.4.1 Running-in ...116
4.4.2 Calculation of wear rate ...117
4.4.3 Classification of the specific wear rate ...118
4.5 SELECTING OR CONSTRUCTING TEST APPARATUS ...125
4.5.1 Pin-on-disc / Pin-on-ring ...126
4.5.2 Pin-on-flat / ball-on-flat ...127
4.5.3 Two disk ...127
4.6 STANDARDS FOR MEASURING FRICTION AND WEAR ...128
4.6.1 Specimen preparation ...128
4.6.2 Experiment ...129
4.6.3 Reporting ...129
4.6.4 Reproducibility ...129

Chapter 5: Machine lubrication and beyond ...133
5.1 LUBRICATION REGIMES ...134
5.1.1 Stribeck curve ...135
5.1.2 Transition diagram ...137
5.2 LUBRICANTS ...138
5.2.1 Physical properties ...138
5.2.2 Additives ...144
5.2.3 Oil supplements ...146
5.2.4 Trends in engine and industrial lubrication ...148
5.3 TYPES OF LUBRICANTS AND LUBRICANT SELECTION ...149
5.3.1 Base oils ...149
5.3.2 Biolubricants ...150
5.3.3 Food grade lubricants ...152
5.3.4 Lubricants for thermoplastics, thermosets and elastomers ...152
5.3.5 Greases ...153
5.3.6 Solid lubricants ...156
5.3.7 Lubricant selections for specific applications ...159
5.4 LUBRICATION MANAGEMENT ...161
5.4.1 Grease versus oil lubrication ...161
5.4.2 Oil lubrication systems ...161
5.4.3 Engine lubrication system ...162
5.5 PREDICTIVE MAINTENANCE AND OIL ANALYSIS ...163
5.5.1 Maintenance engineering ...163
5.5.2 Predictive maintenance ...164
5.5.3 Causes of lubricant deterioration and their prevention ...165
5.5.4 Chemical and physical oil analysis ...166
5.5.4 Wear particle analysis ...167

Chapter 6: Material selection a systematical approach ...173
6.1 MATERIALS IN SLIDING BEARINGS ...174
6.1.1 Selection criteria for metals ...174
6.1.2 Selection criteria for polymers ...177
6.1.3 Selection criteria for technical ceramics ...193
6.2 COATINGS AND SURFACE TREATMENTS ...196
6.2.1 Where surface treatments are applied ...196
6.2.2 Classification of surface treatments ...197
6.2.3 Surface treatment techniques ...198
6.3 MATERIAL SELECTION: A SYSTEMATICAL APPROACH ...205
6.3.1 System identification ...205
6.3.2 Definition of material selection criteria ...205
6.3.3 Pre-selection of materials ...205
6.3.4 Experimental setup ...206
6.3.5 Selection of the best candidate(s) ...206

Chapter 7: Failure analysis ...213
7.1 FAILURE MODES IN ROLLER BEARINGS ...214
7.1.1 Load patterns and their interpretation ...214
7.1.2 ISO failure mode classification ...215
7.1.3 Bearing failures ...216
7.2 FAILURE MODES OF GEARS ...222
7.2.1 ISO failure mode classification ...222
7.2.2 Gear failures ...222
7.3 ANALYSIS TECHNIQUES AND PROCEDURE ...230
7.3.1 Failure analysis cam-follower mechanism ...231
7.3.2 Failure analysis rail-wheel contact, fatigue crack ...234

Part B: Full film lubrication
NOMENCLATURE - PART B ...238

Chapter 8: Introduction to full film lubrication ...239
8.1 FULL FILM LUBRICATION ...240
8.1.1 Introduction ...240
8.1.2 History ...241
8.1.3 Trends ...242
8.2 REYNOLDS’ EQUATION ...243
8.2.1 Effective surface velocity ...246
8.2.2 Film thickness in journal bearings ...248
8.2.3 Viscous shear ...249

Chapter 9: Hydrodynamic lubricated bearings and sliders ...253
9.1 SLIDER BEARINGS ...254
9.1.1 Converging wedge ...254
9.1.2 Michell bearing ...256
9.1.3 Rayleigh step bearing ...259
9.1.4 Tapered land pad ...262
9.1.5 Curved pad ...264
9.2 PLAIN JOURNAL BEARINGS ...265
9.2.1 Bearing performance and design ...265
9.2.2 Design optimization load film thickness versus bearing clearance ...273
9.2.3 Design optimization friction versus film thickness ...275
9.3 SPIRAL GROOVE BEARINGS ...276
9.3.1 Spiral groove journal bearings ...276
9.3.2 Spiral groove thrust bearings ...279

Chapter 10: Squeeze film damping and dynamic response ...287
10.1 SQUEEZE FILM DAMPING ...288
10.1.1 Band on flat ...288
10.1.2 Circular disk on flat ...290
10.1.3 Circular ring on flat ...291
10.1.4 Cylinder on flat ...291
10.1.5 Squeeze film dampers ...292
10.1.6 Journal bearings ...294
10.1.7 Michell bearings ...296
10.2 DYNAMIC RESPONSE ...297
10.2.1 Michell bearings ...298
10.2.2 Piston rings ...300
10.2.3 Journal bearings ...301

Chapter 11: Dynamic sealing systems ...309
11.1 SEALING SYSTEMS ...310
11.1.1 Classification ...310
11.1.2 Operating limits ...310
11.2 ROTARY SEALS ...311
11.2.1 Lip seals, V-rings and O-rings ...311
11.2.2 Mechanical face seals ...313
11.2.3 Seal face patterns ...317
11.2.4 Gap seals ...318
11.2.5 Labyrinth seals ...319
11.3 RECIPROCATING SEALS ...320
11.3.1 Reciprocating lip-seals in hydraulics ...320
11.3.2 Reciprocating lip-seals in pneumatics ...322
11.2.4 O-rings in reciprocating applications ...324
11.3.4 Piston ring-seals in engines ...327

Chapter 12: EHL seals, mechanisms and forming processes ...331
12.1 METAL FORMING PROCESSES ...332
12.1.1 Wire drawing ...332
12.1.2 Sheet metal rolling ...336
12.1.3 Deep drawing ...339
12.2 EHL-ROLLING MECHANISMS ...341
12.2.1 EHL-line contact ...341
12.2.2 EHL-point contact ...344
12.2.3 Roller bearings ...346
12.3 EHL-TRACTION DRIVE MECHANISMS ...347
12.3.1 Plain traction wheels ...350
12.3.2 Crowned traction wheels ...351

Chapter 13: Hydrostatic bearings ...357
13.1 BASIC METHODS OF OPERATION ...358
13.2.1 Methods to obtain bearing stiffness ...359
13.2.2 Advantages and limitations of pressurised fluid bearings ...360
13.2 DESIGN OF HYDROSTATIC BEARINGS ...361
13.2.1 Basic construction elements ...361
13.2.2 Hydrostatic thrust bearings with shallow pocket ...366
13.2.3 Hydrostatic thrust bearings with tapered film ...367
13.2.4 Hydrostatic thrust bearings with capillary restrictor ...367
13.2.5 Hydrostatic thrust bearings with orifice restrictor ...372
13.2.6 Hydrostatic preloaded thrust bearings ...375
13.2.7 Hydrostatic journal bearings with external restrictors ...377
13.2.8 Hydrostatic journal bearings with shallow pockets ...381

Chapter 14: Aerostatic bearings ...389
14.1 BASIC METHODS OF OPERATION ...390
14.1.1 Methods to obtain bearing stiffness ...391
14.1.2 Advantages and limitations of pressurised gas bearings ...393
14.2 DESIGN OF AEROSTATIC BEARINGS ...394
14.2.1 Basic construction elements ...394
14.3.2 Aerostatic thrust bearings with shallow pocket ...397
14.3.2 Aerostatic thrust bearings with partial grooved surface ...397
14.3.3 Aerostatic thrust bearings with tapered-film ...398
14.3.4 Aerostatic thrust bearings with orifice restrictor ...399
14.3.5 Aerostatic thrust bearings with porous restrictor ...400
14.3.6 Aerostatic journal bearings with porous ring restrictor ...401
14.3.7 Aerostatic journal bearings with two porous ring restrictors ...403
14.3.8 Design of a pneumatic cylinder with aerostatic piston bearing ...405

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