Process by which the friction in a moving contact is reduced. Five distinct form of lubrication are:
Hydrodynamic Hydrostatic Elastohydrodynamic Mixed Boundary Solid film
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Solid-film
Boundary lubrication, <1 Mixed lubrication, 1<<3 Hydrodynamic lubrication, >5 Elastohydrodynamic , 3<<5
Hydrostatic
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Root-mean-square deviation
1 l 2 Rq = 0 z (x ) dx l
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f = 1 . 07 * [ =
II
]2 / 3
E is young
modulus,
Mpsi Mpsi
0.6558
3 . E + 4 .G G (3 .* E + G )
G is modulus
in shear,
0.5039
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Adhesion = Attractive force across an interface Interface = Contact boundary between two surfaces.
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ADHESION Theory
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ADHESION Theory
Two surfaces are pressed together under load W. Material deforms until area of contact (A) is sufficient to support load W. A = W/H. To move the surface sideway, must overcome shear strength of junctions with force F F=As
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W = Areal H
F = Areal s
s H
For most of materials H = 3y & s = y /1.7321 Expected value of =.2 Friction of metals arises from strong adhesion or welding at the regions of real contact. Similar & dissimilar materials?????
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PLOUGHING Effect
Ploughing occurs when two bodies in contact have different hardness. The asperities on the harder surface may penetrate into the softer surface and produce grooves on it, if there is relative motion.
Assume n conical asperities of hard metal in contact with flat soft metal, vertically project area of contact:
W = n(0.5 * r ) H
2
A = n 0.5 * r 2
F = (nrh) H
cot
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Slope of real surfaces are nearly always less than 10 (i.e. > 80), therefore < 0.1. Conclusion: Total , representing contribution for
both ploughing and adhesion terms, should not exceed 0.3. For same material, = 0.2.
Junction Growth
A. y =
Constant
2 + F 2
F =f (A) ????
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Limiting Junction Growth Presence of weak interfacial films. Assume shear stress, i.
Fmax = i Amax
Fmax i Amax = = 2 2 W ( y 4 i2 ) Amax
W 2 A. y = + F 2
2 2 ( y i2 )
Understanding this mechanism motivate to apply thin film of low shear strength materials to the surfaces.
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= 0.01 0.1
for elastohydrodynamic lubrication = 0.001 0.01 Coefficient of friction for hydrodynamic lubrication ???
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Hydrodynamic
Hydrostatic
Axial coordinate
Axial coordinate
Hydrodynamic
Relative motion between two mechanical surfaces is utilize the generate pressure and levitate one surface relative to other surface. Self-acting Load support is a function of lubricant viscosity. HDL provided an infinite bearing life Able to damp the external vibrations. Requires lubricant flow to compensate the leakage from bearing ends. Significant difference in static & kinetic friction coefficients High relative speed generates much higher load capacity & destabilize the shaft-system.
Hydrostatic
External source of pressurized fluid is required to levitate the shaft surface and separate it from bearing surface.. Costly Load support is a weak function of lubricant viscosity.
Infinite life if supporting ancillary equipments function well Able to control the effect of external vibration.. Active control
Almost same value of coefficient of frictions. Very good control on the shaft position.
VISCOSITY
Constant of proportionality
To define viscosity consider surface 1 is moving with a velocity V on a film of thickness h. Imagine film is composed of series of horizontal layers and force F causing these layers to deform/slide on one another just like a deck of card.
du = ; dy
=
2
m in Pa.s ; in s
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Viscosity
Physical property-resistance to flow. Due to internal friction and molecular phenomena . Dynamic Viscosity
o 1 cP=10-3 Pa.s
Kinematic Viscosity
o 1 cSt = 1 mm2/s
Grades of Oils:
SAE (Society of Automotive Engineers) ISO
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Petroffs Equation
Friction = Shear Stress * Area F = (Viscosity* V/h)*Area
V = 2RN ; A = 2RL C F Coefficient of friction, = W * 2RN * 2RL / C = 2 RLP Conclusion: Coefficient of 2 N R = 2 friction is a function of P C speed, load and viscosity Friction force, F =
* 2RN * 2RL
C is radial clearance
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Temperature Rise
Friction, due to shear of lubricant film, generates heat (FV)) in lubricant oil and increases the temperature of lubricant. Assuming that total generated heat is carried by the oil flowing through bearing
Heat generated = Heat convected by oil flow (2 R N )(2 R L ) (2 R N ) = m CP t C or t =
(2 R )3 N 2
C m CP
= 860 kg / m3
C P = 1760 J / kg oC R = 1000 C
(2 R )3 N 2 or t = L 2RN C C L CP 8 2 N R or t = ( ) C P C
( )
t = 52.2 N
t = 52.2 N t = 783
SAE grade 25.5258 48.7809 78.3000 109.6200 29.7540 51.9912 60.3693 91.6110 10W 20W SAE 30 SAE 40 5W-20
Viscosity in Viscosity in mPa.s 400c mPa.s 1000c 32.6 62.3 100 140 38 5.57 8.81 11.9 14.7 6.92 10.2 14.4 20.5 4.3660 6.8982 9.3177 11.5101 5.4184 7.9866 11.2752 16.0515
Logarithmic scale
VISCOSITY INDEX: Qualitative comparison index VI relates viscosity change at 37.8 0c and 98.90c. Pennsylvanian oil~VI=100 gulf coast oil ~ VI=0
VI = L-U *100 L-H
An oil with VI = 240 has less rate of viscosity change with temperature compared to oil with VI 100.
361
= in e
(t tin )
log e in = (t tin )
SAE grade 10W 20W SAE 30 SAE 40 5W-20 10W-30 10W-40 10W-50
Viscosity In mPa.s 1000c 400c 32.6 62.3 100 140 38 66.4 77.1 117 5.57 8.81 11.9 14.7 6.92 10.2 14.4 20.5
= 0 exp( p )
Reynolds Equation
A basic pressure distribution equation for Fluid Film Lub. In 1886, Reynolds derived for estimation of pressure distribution in the narrow, converging gap between two surfaces. Reynolds equation helps to predict hydrodynamic, squeeze, and hydrostatic film mechanisms.
Reynolds' equation h 3 P h 3 P + = 6 (U 1 + U 2 )h + (W1 + W2 )h + 2(Vh V0 ) x x z z z x
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365
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u P On integration : y + C1 = y x P y 2 + C1 y + C2 u = x 2
Using boundary conditions : y = 0, u = U 2 ; y = h, u = U 1
P u = x y y
U 2 = C 2 ,
(U1 U 2 ) P h
h x 2 y 2 yh P y u = x + (U1 U 2 ) h + U 2 2
= C1
Check !!!
368
h 3 P h qx = + (U1 + U 2 ) 12 x 2
Similarly flow rate in z - direction q z = w.dy
0 h
Check !!!
h 3 P h qz = + (W1 + W2 ) 12 z 2
Stretching action
Simplification I : h 3
1 P = 6(U1 + U 2 ) h z z x
Squeeze action (bearing surfaces move perpendicular to each other) Can carry High loads for short duration
h 3 P Simplification II : x = 6(U1 + U 2 ) x h x
Comparison among pressure profiles at z = 0 7000000 6000000 5000000 Pressure 4000000 3000000 2000000 1000000 0 0 20 40 60 80 100 120 140 160 180
plong in green color
Simplification II
Simplification I
Comparison among pressure profiles at z = 0 1.4E8 1.2E8 1E8 Pressure 8E7 6E7 4E7 2E7 0 0 20 40 60 80 100 120 140 160 180
pshort in red
Simplification I
Simplification II
Comparison among pressure profiles at z = 0 22000000 2E7 18000000 16000000 14000000 Pressure 12000000 1E7 8000000 6000000 4000000 2000000 0 0 20 40 60 80 100 120 140 160 180
pshort in red
Simplification I
Simplification II
Length/diameter = 1.0
2 P 6U dh = 3 2 z h dx
dp 6U dh = 3 z using symmetry condition dp/dz = 0 at z = 0 dz h dx
3U dh 2 L2 z p= 3 4 h dx using p = 0 at z = L/2
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Film thickness, h, depends on geometry of tribo-pair. For example, in journal bearing h = Cr + e cos
Using expression of h in following equation 3U dh 2 L2 z p= 3 4 h dx
2 2 L z 4
3U sin p= 2 3 R Cr (1 + cos )
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UL W = 4Cr2 1 2
3
16 2 2 1 + 1
1/ 2
Wr 1 2 tan = tan = W 4
Eccentricity ratio
F=
2ULR Cr 1 2
Cr Wr 2R
UL3 Wr = 4Cr2 1 2
If
0, F
Petroff solution
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Temperature Rise
Friction, due to shear of lubricant film, generates heat (FV)) in lubricant oil and increases the temperature of lubricant. Assuming that total generated heat is carried by the oil flowing through bearing
Heat generated = Heat convected by oil flow F (2 R N ) = m C P t or F (2 RN ) 2RN Cr L C P 2 2F t = ( Cr L ) C P t = t = 1 F 756800 (Cr L )
= 860 kg / m3
C P = 1760 J / kg oC
or or
1. Guess eccentricity ratio 2. Calculate load capacity, friction force, temperature rise. 3. Modify lubricant viscosity. 4. Repeat steps 1-3 so that average viscosity and load converge.
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Ex: Determine the minimum film thickness, maximum pressure, coefficient of friction for a hydrodynamic journal bearing, which supports a 600 N load at rotational speed of 2000 rpm. The shaft dia is 40 mm. Assume bearing length = 10 mm, oil viscosity at room temp (30C) = 15 mPa.s, =0.029, and radial clearance 20 m. Given: U = 4.19 m/s. Factor1 = U*L3**0.25/(Cr2)=8227 m2 /s, Factor2 = 2*U*L*R*pi()/Cr , STEP 1: Assume = 0.5 Assume = 0.75 STEP 2: Assume = 0.8 W = 118 N W = 562 N W = 900 N, F = 6.76 N, t=44.68C
W = (Factor1)
F=
(Factor 2)
1
2
(Factor1)Cr +
2R
(1 )
2 2
16 2 2 1 + 1
1/ 2
(1 )
2 1 .5
t =
1 F 756800 (Cr L )
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= in e
(t tin )
at t = 44.68o C = 0.0041
STEP 4: For = 0.8 W = 246 N, F = 1.85 N, t=12.22C, =0.0105 W = 630.2 N, F = 4.74 N, t=31.3C. Now it is preferable to increase . Let us assume = 0.82 and t=30 C W = 471.4 N, F = 2.99 N, t=19.75C, =0.0085 W = 636 N, F = 4.0 N, t=26.6C. =0.0069 W = 516.3 N, F = 3.3 N, t=21.63C. Now it is preferable to increase . Let us assume = 0.83 and t=25 C W = 615.3 N, F = 3.56 N, t=23.5C.
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Ex: Determine the minimum film thickness, maximum pressure, coefficient of friction for a hydrodynamic journal bearing, which supports a 600 N load at rotational speed of 2000 rpm. The shaft dia is 40 mm. Assume bearing length = 10 mm, oil viscosity at room temp (30C) = 15 mPa.s, =0.029, and radial clearance 20 m. Assume dia of feed oil is 2.5mm and supply pressure is 1.5 bar Given: U = 4.19 m/s. Factor1 = U*L3**0.25/(Cr2)=8227 m2 /s, Factor2 = 2*U*L*R*pi()/Cr , STEP 1: Assume = 0.5 Assume = 0.75 STEP 2: Assume = 0.8 W = 118 N W = 562 N W = 900 N, F = 6.76 N
W = (Factor1)
F=
(Factor 2)
1 2
(Factor1)Cr +
2R
(1 )
2 2
16 2 2 1 + 1
1/ 2
(1 )
2 1 .5
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Heat generated = Heat convected by oil flow F (2 R N ) = m C P t or F (2 RN ) 2RN Cr L + QP C P 2 27.64 F t = 4.189 + 0.254 (1 + )3 t =
= 860 kg / m3
C P = 1760 J / kg oC
or
t = 33o C
QP = 2.54 10 8 (1 + ) m3 / s
3
= in e (t tin )
at t = 33o C = 0.0058
STEP 4: For = 0.8 W = 348 N, F = 2.615 N, t=12.75C, =0.0104 W = 624.2 N, F = 4.7 N, t=22.9C.
Now it is preferable to increase . Let us assume = 0.82 and t=23 C W = 576.13 N, F = 3.65 N, t=17.66C, =0.009 W = 673.4 N, F = 4.27 N, t=20.6C. =0.0083 W = 621 N, F = 3.94 N, t=19C.