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Training on Bearing and Lubrication

Bab V Plain Bearing

5.1 Pendahuluan
1. Aplikasi
Kompresor, pompa, motor berkapasitas besar Turbine Generator dll.

2. Jenis-jenis
Journal/Radial Bearing beban radial poros Thrust Bearing beban aksial poros Guide/Slipper Bearing pengarah gerak
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3. Prinsip Kerja
Sliding Murni tanpa ada cairan/gas pelumas (contoh: Teflon, Nylon, Graphite) Hydrodynamic terdapat lapisan batas antar permukaan Hydrostatic terdapat pelumas bertekanan yang memisahkan kedua permukaan Kombinasi Hydrodynamic dan Hydrostatic

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4. Perbandingan Umum vs Roller Bearing

Kelebihan:
Bentuk yang kompak Operasi lebih halus Lebih murah untuk produksi massal Lebih kaku Umur relatif tidak dibatasi fatigue

Kekurangan:
Gesekan besar untuk start awal Memerlukan pelumas kualitas tinggi Rentan terhadap lingkungan buruk (partikel asing dll.)

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5.2 Sliding Bearing

1. Requirement Material untuk sliding: Fatigue resistance
Kemampuan material untuk menahan beban berulang tanpa mengalami keretakan/kegagalan

Embeddability
Kemampuan material untuk menyerap partikel asing dalam pelumas sehingga scoring/aus dapat dihindari

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Anti-scoring tendency
Kemampuan material untuk menahan galling atau seizing pada kontak metal-metal saat start-up

Conformability
Kemampuan material untuk mengalami creep atau perubahan bentuk menyesuaikan kontour permukaan maupung pembebanan yang tidak uniform saat running (misal: misalignment)

High thermal conductivity

Kemampuan material untuk mengeluarkan panas yang timbul dari gesekan sehingga temperatur stabil
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Wear resistance
Ketahanan material terhadap aus, berhubungan dengan umur

Corrosion resistance
Ketahanan material terhadap zat korosif yang kadang terkandung/terbentuk dalam pelumas

Load capacity
Kemampuan material untuk menahan beban tekan

Thermal Expansion coef.

Untuk menghindari pemuaian dan thermal stress yang berlebih

Lain-lain
costs, availability, machinability

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2. Jenis Material
Logam
Aluminium Babits (tin alloys) Copper alloys Zinc Iron

Non-logam
Plastics Carbon/graphites Cemented carbides Self-lubricated materials
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3. Perbandingan Material Sliding

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5.3 Hydrodynamic Bearing

1. Mekanisme Kerja Komponen:
Journal / Poros Bushing / Bantalan Pelumas

Pressure Distribution & Pemodelan

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2. Mode Operasi
Kondisi pelumasan yang terjadi pada sistem hydrodynamic bearing Tergantung dari pelumas, rancangan bantalan dan kecepatan putar poros Terdiri dari:
Full-film Boundary Lubrication Mixed

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Full-film
Pelumas mampu memisahkan secara sempurna kedua permukaan gesek Koefisien gesek rendah ( = 0.001 0.005) Keausan rendah Parameter yang harus dipenuhi meliputi:
Pemilihan pelumas yang tepat untuk kondisi operasi Aliran pelumasan yang terpelihara baik Perancangan dan pemilihan bantalan yang tepat Kecepatan relatif kedua permukaan terjaga sekira 25 feet/min

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Boundary Lubrication
Permukaan sliding saling bergesekan dengan hanya dibatasi oleh lapisan pelumas yang sangat tipis Cukup baik untuk peralatan dengan gerak osilasi atau rotasi putaran rendah (< 10 feet/min) Koefisien gesek, = 0.08 0.14 Umumnya menggunakan pelumas grease atau oli dengan maintenance regular

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Mixed Film-Boundary Lubrication

Mode operasi terjadi antara mode full-film maupun boundary, tergantung kondisi operasi bearing Terjadi pemisahan sebagian antar permukaan sliding Koefisien gesek, = 0.02 0.08 Rotasi putaran minimal 10 feet/min

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Perbandingan tiga mode operasi

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Dalam operasi, semua mode pelumasan terjadi:

Saat journal berhenti, terjadi kontak antar permukaan sliding Saat start-up dan stop, terjadi mode boundary lubrication Seiring bertambahnya kecepatan putar, terjadi mixed film-boundary Pada kecepatan rancangan, terjadi full-film lubrication

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3. Journal Bearing
Menahan beban radial journal/poros Grooving:
Untuk menjaga agar pelumas tetap berada diantara journal dan bantalan Juga berfunsgi sbg pendingin pelumas Lokasi pemasukan pelumas ke dalam bearing haruslah pada daerah bertekanan rendah

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Konstruksi
Circumferential grove alur pada sekeliling bantalan Cylindrical overshoot alur lebar untuk pendinginan bearing aplikasi kecepatan tinggi Pressure dengan tambahan alur setengah lingkaran untuk mengatur tekanan pelumasan Multiple groove beralur banyak untuk memperlancar aliran pelumas
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Elliptical
Terdiri dari 2 bagian membentuk penampang ellips

Elliptical overshoot
Model Ellips dengan alur melebar

Three-lobe
Mirip elliptical tetapi dengan 3 rongga yang lebar

Pivoted Shoe
Bearing dengan 3 atau lebih permukaan yang terpisah dengan titik putar pada sumbu poros

Nut-cracker
Bearing terdiri dari 2 bagian dengan bagian atas bisa bergerak bebas dalam arah vertikal

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Parameter Performans Journal Bearing:

Bearing load capacity Frictional losses Lubricant flow requirement Kenaikan temperatur

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Journal Bearing Notation

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Procedure for Lubrication Analysis

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Dari hasil penghitungan & Grafik, kondisi cd yang dapat diterima:

d 1 : cd min. 200 mikroinch 1 d 4 : cd min. 500 mikroinch d 4 : cd min. 750 mikroinch

cd ditentukan pada T = 400 F dari kurva oil

temperature jika dalam manual tidak terdapat persyaratan khusus Toleransi pembebanan dari manufacturer bisa dimodifikasi asal masih dalam range h0 dan T

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Contoh Soal

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4. Thrust Bearing
Fungsi:
Menahan poros arah aksil Memposisikan poros pada arah aksial

Konsep

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Klasifikasi berdasarkan Geometri

1.

Parallel/Flat
Paling umum, sederhana dan murah Aplikasi beban/energi rendah Umum untuk

positioning devices
2.

Step
Sederhana, relatif murah Sensitif terhadap

misalignment
Dimensi kecil

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3.

Tapered-land
Kapasitas besar Performance bagus untuk dimensi besar Perlu alignment yang bagus Relatif mahal

4.

Tilting pad
Kapasitas besar Relatif mahal Mampu mengakomodasi misalignment

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Load range applications

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Thrust Bearing Notation

a b b2 B c D e f g h i J
= radial width to pad, inches = circumferential length of pad at pitch line, inches = pad step length = circumference of pitch circle inches = specific heat of oil, Btu/gal/oF = diameter, inches = depth of step, inch = coefficient of friction = depth of 45o chamfer, inches = film thickness, inch = number of pads = power loss coefficien
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= film thickness factor

Kg = fraction of circumference occupied by the pads;

usually, 0.8

l M N O p ps Pf Q

= length of chamfer, inches = horsepower per square inch = revolutions per minute = operating number = bearing unit load, psi = oil-supply pressure, psi = friction horsepower = total flow, gpm

Qc = required flow per chamfer, gpm Qc0 = uncourrected required flow per chamfer, gpm QF = film flow, gpm
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s t U V W YG YL YS
Z

= oil-groove width = temperature rise, oF = velocity, feet per minute = effective width-to-length ratio for one pad = applied load, pounds = oil-flow factor = leakage factor = shape factor = viscosity, centipoises = dimensionless film-thickness factor = taper = kinetic energy correction factor

Note : In the following, subscript 1 denotes inside diameter and subscript 2 denotes outside diameter. Subscript i denotes inlet and subscript o
denotes outlet.

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Procedure for Thrust Bearing Lubrication Analysis

1. Flat Plat Bearing

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2. Step Bearing

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3. Tapered

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4. Tilting Pad

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5.4 Hydrostatic Bearing

Pada Hydrodynamic bearing, perlu kecepatan relatif permukaan yang tinggi untuk membentuk film pelumas yang bertekanan Jika bearing dengan beban besar tetapi dengan kecepatan relatif permukaan rendah, maka perlu tekanan eksternal agar tidak terjadi kontak langsung antar permukaan gesek Khususnya pada saat start up atau shut down, aplikasi Hydrostatic diperlukan, yaitu dengan menambahkan tekanan eksternal pada bearing

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Mekanisme pembentukan film pada hydrostatic bearing

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Kelebihan
Koefisien gesek sangat rendah Dapat menerima beban yang sangat tinggi, tidak tergantung kecepatan Akurasi tinggi pada kecepatan tinggi, beban rendah Kekakuan bearing tinggi

Kekurangan
Memerlukan pompa tekanan dan kecepatan alir tinggi

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Aplikasi
Teleskop besar, radar tracking unit
Beban sangat besar Kecepatan sangat rendah

Machine tools dan giroskop

Beban rendah Kecepatan sangat tinggi

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Gas-lubricated hydrostatic bearing

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Kelebihan
Gesekan dan viscous resistance yang sangat rendah Pelumas gas/udara, sehingga sederhana dan bersih Tidak ada kontaminasi pelumas terhadap permukaan Pelumas dapat bekerja baik range temperatur yang sangat besar Tidak terjadi fenomena kavitasi

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Kekurangan
Kapasitas beban rendah Pengerjaan permukaan harus halus Alignment harus sangat baik Dimensi dan clearance harus sangat akurat Stabilitas relatif rendah

Aplikasi
Gas-cycled machinery Gyroscope Food-processing Textile processing
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5.5 Ringkasan Plain Bearing

1. Perbandingan
Condition General Comments Bearing Type Hydrodynamic Hydrostatic Self-acting Gas Externally Presurised

High temperature

Attention to differential expansions and their effect on axial clearance is necessary Attention to differential expansions and starting torque is necessary

Attention to oxidation lubricant is necessary resistance of Excellent

Excellent

Excellent

Low temperature

Lubricant may impose limitations; consideration of starting torque is

Lubricant may impose limitations

Exellent: thorough drying of gas is necessary

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Condition External vibration

General Comments Attention to possibility of fretting damage is necessary (exepts for hydrostatic bearings) -

Bearing Type Hydrodynamic Statisfactory Hydrostatic Excellent Self-acting Gas Normally satisfactory Externally Presurised Excellent

Space requirements

Small radial extent but total space requirement depends on lubricant feed system

Small radial extent

Small radial total space requirement depends on gas feed system Satisfactory

Dirt of dust

Statisfactory; filtration on lubricant is important

Sealing is important

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Condition Vacuum

General Comments -

Bearing Type Hydrodynamic Hydrostatic Self-acting Gas Not normally applicable Externally Presurised Not applicable when vacuum has to be maintained Satisfactory

Lubricant may impose limitations

Wetness and humidity

Attention to posibility of metallic corrosions is necessary -

Satisfactory

Satisfactory

Radiation Low starting torque High starting torque Accuracy of radial location

Lubricant may impose limitations Satisfactory Satisfactory Good Excellent Satisfactory Excellent

Excellent Excellent Excellent Good Excellent Excellent Excellent

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Condition Life

General Comments -

Bearing Type Hydrodynamic Theoretically infinite but affected by filtration and number of start - stops Hydrostatic Theoretically infinite Self-acting Gas Theoritically infinite but affected by number of start- stops Externally Presurised Theoretically infinite

Combination of axial and radial load capacity Silent running

A journal bearing surface must be provided to carry radial loads and thrust face to carry axial loads

Excellent

Excellent except for possible pump noise

Excellent

Excellent except for possible compresor noise

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Bearing Type Hydrodynamic Self-contained assemblies can be used with certain limits of load,speed and diameter; beyond this, oil circulation is necessary Good Hydrostatic Auxiliary high pressure is necessary Self-acting Gas Excellent Externally Presurised Pressurized supply of dry, clean gas is necessary

Condition Simplicity of lubrication

General Comments -

Availability of standard parts Prevention of contamination of product and surroundings Tolerance to manufacturing and assembly inaccuracies

Poor

Good Excellent

Poor Excellent

Normally statisfactory,but attention to sealing is necessary, exept where process liquid can be used as lubricant Poor Satisfactory

Poor

Satisfactory

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Condition Type of motion Frequent Start-stops Unidirectional Bidirectional Oscillatory Running costs

General Comments

Bearing Type Hydrodynamic Hydrostatic Self-acting Gas Externally Presurised Exellent Suitable Suitable Some types are suitable Unsuitable Suitable Suitable Suitable

Good Suitable Some types are suitable Unsuitable

Suitable

Depends on complexity

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2. Aplikasi Praktis
Panduan Pemilihan Bearing dalam Grafik

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Keterangan

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Pemilihan Plain Bearing menurut operasi

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Panduan Pemilihan Thrust Bearing

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Panduan Pemilihan Material

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5.6 Metode Pemasangan

Faktor-faktor yang harus dipertimbangkan:
Keseragaman tebal dinding bantalan Kontak yang baik dan luas dengan housing, untuk perpindahan panas Perubahan bentuk bearing akibat kenaikan temperatur

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Beberapa Metode
Press / Shrink-fit Keys: Set screws, Woodwurf keys, bolted, threaded bearing, dowel pins, housing caps

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5.7 Pelumasan
1. Metode Pelumasan
Pressure/pompa
Pelumas bertekanan diinjeksikan ke arah permukaan kontak melalui alur atau lubang Tekanan umumnya pada 50 psi Untuk mode film-lubrication, perpindahan panas cukup baik dan kemampuan pembersihan kotoran yg baik

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Splash-fed
Pelumas dipercikkan ke bearing Biasanya digunakan untuk pelumasan bearing/bushing yang berselang (tidak terus menerus) Praktis untuk kondisi housing yang sempit dan bagian bergerak tidak dapat terendam pelumas

Oil-bath
Bushing/bearing terendam pelumas Kehandalan setinggi pressure lubrication Housing memungkinkan Putaran bagian berputar tidak terlalu tinggi
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Oil-ring
Pelumas disuplai ke bantalan melalui ring yang berkontak dengan bagian berputar Rentang kecepatan tangensial 200 2000 feet/min.

Wick-pack
Pelumas disuplai ke bantalan dengan prinsip kapiler melalui sumbu (wick) Jumlah pelumas yang dialirkan proporsional dengan ukuran sumbu

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Grease pack
Menggunakan grease dan bantalan berpori Pelumasan permanen, tetapi hydrodynamic sulit tercapai Biasanya sampai mode boundary lubrication

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2. Pelumas
Nilai pelumasan untuk sliding bearing terutama tergantung pada kapasitas pembentukan lapisan film pelumas antar permukaan sliding Karakteristik terbentuknya film pelumas tergantung terutama pada viskositas Idealnya: pelumas dengan viskositas (kekentalan) rendah sehingga rugi gesek rendah tetapi tidak pecah pada film Kenyataannya kompromi
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Satuan Viskositas

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Pengaruh Temperatur terhadap viskositas

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Faktor-faktor dalam pemilihan pelumas

Mode operasi yang diharapkan Kecepatan relatif permukaan gesek Beban yang bekerja

Misal: Bantalan dengan beban ringan, diharapkan terjadi mode full-film pada putaran 2000 rpm, maka pelumas yang cocok adalah: SAE 5

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3. Grease
Kondisi Operasi:
Putaran rendah dan beban besar Boundary lubrication Koefisien gesek: 0,08 0,18 (rata-rata 0,12)

Kelebihan
Periode pelumasan yang panjang Terhindar dari kontaminasi akibat kebocoran oli Efektif untuk lingkungan yang relatif kurang bersih

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4. Solid Lubricant
Material dengan tahanan geser yang rendah Untuk peralatan yang bekerja pada temperatur tinggi Sifat pelumasan berubah drastis jika mendekati titik cair:
Koefisien gesek bisa meningkat 5 10 kali Laju metal transfer meningkat 1000 kali

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