THE TRIBOLOGY HANDBOOK pot

MICHAEL J NEALE 1 HWLU"""4 L SECOND EDITION THE TRIBOLOGY HANDBOOK THE TRIBOLOGY HANDBOOK Second edition Edited by M. J. NEALE (>BE, BSc(Eng), DIC, FCGI, WhSch, FEng, FlMechE qUTT E R WO RT H EINEMANN Butterworth-Heinemann Linacre House, Jordan Hill, Oxford OX2 8DP 225 Wildwood Avenue, Woburn MA 0 180 1-204 1 A division of Reed Educational and Professional Publishing Ltd -@A member of the Reed Elsevier plc group OXFORD AUCKLAND BOSTON JOHANNESBURG MELBOURNE NEW DELHI First published 1973 Second edition 1995 Reprinted 1997, 1999 Transferred to digital printing 200 1 0 The editor and contributors 1973, 1995 All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means and whether or not transiently or incidentally to some other use of this publication) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988 or under the terms of a licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court Road, London, England, WIP OLP. Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to the publisher British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library Library of Congress Cataloguing in Publication Data A catalogue record for this book is available from the Library of Congress ISBN 0 7506 11 98 7 For information on all Butterworth-Heinemann publications visit our website at www.bh.com Printed in Great Britain by Antony Rowe Ltd, Eastboume ~~- Contents Editor's Preface List of Contributors Selection of bearings AI A2 Selection of journal bearings A3 Selection of thrust bearings Selection of bearing type and form Plain bearings A4 A5 A6 A 7 A8 A9 A10 AI 1 A12 A13 A14 A15 A16 A17 A18 A19 Plain bearing materials Dry rubbing bearings Porous metal bearings Grease, wick and drip fed journal bearings Ring and disc fed journal bearings Steady load pressure fed journal bearings High speed bearings and rotor dynamics Crankshaft bearings Plain bearing form and installation Oscilhtory journal bearings Spherical bearings Plain thrust bearings Psofiicd pad thrust hearings Tilting pad thrust bearings Hydrostatic bearings Gas bearings Rolling bearings A20 Selection of roiling bearings A21 Rolling hearing materials A22 Rolling bearing installation Special bearings A23 Slide bearings A24 Instrument jewels A25 Flexures and knife edges A26 Electromagnetic bearings A27 Bearing surface treatments and coatings Rotary driives B1 B2 B3 B4 B5 B6 B7 $8 Belt d.rives Roller chain drives Gears Flexible couplings Self-synchronising clutches One way clutchrs Fricticln clutches Brakes inear drives B9 BIO B1 I B12 B13 B14 Bl5 BlFi B17 B18 Screws Cams and followers Wheels rails and tyres Capstans and drums \Vire ropes Control cablcs Ihmping dcviccs Pistons Piston rings Cvlinders and lincrs Seals B19 B20 B2 1 B22 B23 B24 B25 B26 B27 Selection of seals Sealing against dirt and dust Oil flinger rings and drain grooves Labyrinths, brush seals and throttling bushes Lip seals Mechanical seals Packed glands Mechanical piston rod packings Soft piston seals Lubricants Cl Selection of lubricant type C2 Mineral oils C3 Synthetic oils C4 Greases C5 Solid lubricants and coatings C6 Other liquids Lubrication of components C7 Plain bearing lubrication C8 Rolling bearing lubrication C9 C10 Slide lubrication C 1 1 C12 Wire rope lubrication Gear and roller chain lubrication Lubrication of flexible couplings Lubrication systems CP3 Selection of lubrication sl'sterns C14 Total loss grcase systrms C15 C16 Dip splash s);stem\ CP7 klist systems C18 Circulation systems C 19 Commissioning lubrication systems Total loss oil and fllrid Kreasr systcms Lubrication system components C20 Design of storage tanks C21 Selection of oil pumps 622 C23 C24 C25 Selection of filters and centrifuges Selection of heaters and coolers ,4 guide to piping design Selection of warning and protection devices Operation of lubrication systems and machines C26 Running-in procedures C27 C28 Biological deterioration of lubricants C29 C30 Lubrication maintenance planning Luhricant change periods and tests Lubricant hazards; fire, explosion and health Environmental effects C31 High pressure and vacuum C32 High and low temperatures C33 IYorld ambient climatic data Contents C34 Industrial plant environmental data C35 Chemical effects C36 Storage Fai I u res D1 D2 D3 D4 D5 D6 D7 D8 D9 Failure patterns and failure analysis Plain bearing failures Rolling bearing failures Gear failures Piston and ring failures Seal failures Wire rope failures Brake and clutch failures Fretting problems Maintenance D10 Maintenance methods D11 Condition monitoring D12 Operating temperature limits D13 Vibration analysis D14 Wear debris analysis Dl 3 Performance analysis D16 Allowable wear limits Repair D17 Repair of worn surfaces D18 Wear resistant materials D19 Repair of plain bearings D20 Repair of friction surfaces D21 Industrial flooring materials Basic information El E2 E3 E4 E5 E6 E7 E8 The nature of surfaces and contact Surface topography Hardness Friction mechanisms, effect of lubricants Frictional properties of materials Viscosity of lubricants Methods of fluid film formation Mechanisms of wear Design reference E9 E10 Shaft deflections and slopes El 1 E12 Heat dissipation from bearing assembles Shape tolerances of typical components SI units and conversion factors Index Editor's Preface This second rlwised edition of the Tribology Handbook follows the pattern of the original, first published over twenty years ago. It aims to provide instant access to essential information on the performance of tribological components, and is aimed particularly at designers and engineers in industry. Tribological Components are those which carry all the relative movements in machines. Their performance, therefore, makes a critical contribution to the reliability and efiiciency of all machines. Also because they are the local areas of machines, where high forces and rapid movements are transmitted simultaneously, they are also the components most likely to fail, because of the concentration of energy that they carry. If anything is wrong with a machine or its method of use, these components are the mechanical fuses, which will indicate the existence of a problem. If this happens, guidance on the performance that these components would be expected to provide, can be invaluable. Designers of machines should also find the contents helpful, because they provide an atlas of component performance, aimed at providing the guidance needed when planning the feasibility of various possible layouts for a machine design. In a book of this size it is not possible to cover the whole of the technology of tribological components. More focused design procedures, standards and text books will do this, and hopefully guide engineers in how to get their designs close to the optimum. In a sense the objective of this handbook is to make sure that they do not get it wrong. The format of the book is original and has possibly set an example on the presentation of technical information in the form of an atlas. Like an atlas it is intended to provide guidance on where you are or should be? more or less at a glance, rather than to be read like a novel from cover to cover. The presentation of information in this form has been quite a challenge to the contributors who have responded well and the editor would like to record his appreciation of their work and of all the people who have helped him in the preparation of the book. The editor, who has spent over forty years solving problems with machinery around the world, has found the information in this book of tremendous value. He hopes that it will be equally helpful to its readers with both design and problem solving. For those engineers in countries. who are now moving towards industrialisation, it is hoped, also, that it will provide a useful summary of the experience of those who have been doing it for a little longer. Michael NeaIr Neale Consulting Engineers Ltd Farnham, Surrey UK [...]... in the axial direction Porosity values are quoted as average porosity, and the porosity at the ends of the bearing is less than in the centre As most properties are a function of the porosity, the effect of the porosity gradient on the performance has to be separately considered The dimensional tolerances are also a function of the porosity gradient, wall thickness, length-to-diameter ratio, composition,... these preferred standards for which the design data in Fig 6.3 and 6.4 apply Having made the choice, check with the manufacturers that at the wall thickness and length-to-diameter ratio, the static load capacity is acceptable The length, diameter and composition determine the minimum wall thickness which can be achieved, and avoid a very large porosity gradient in the axial direction Porosity values... guidance on the type of bearing which has the maximum load capacity at a given speed and shaft size I t is based on a life of 10 OOO h for rubbing, rolling and porous metal bearings Longer lives may be obtained at reduced loads and speeds For the various plain bearings, the width is assumed to be equal to the diameter, and the A2.1 lubricant is assumed to be a medium viscosity minerd oil In many cases the. .. filled PTFE’s and other plastics containing PTFE, graphite or MoS,; decreases wear of thermoplastics and thermosets without solid lubricant fillers A5.4 - Porous metal bearings A6 DESIGN AND MATERIAL SELECTION Having determined that a self-lubricating porous metal bearing may be suitable for the application, use Fig 6.1 to assess whether the proposed design is likely to be critical for either load capacity... alllow relative movement between the components of ma.chines, while providing some type of location between them AI T h e form of bearing which can be used is determined by the n a t u r e of the relative movement required and the type of constraints which have to be applied to it Rektive movement between machine components and the constraints applied Conrtraznt applied to the movement Continuow movement... movement Oscillating mouement About a point The movement will be a rotation, and the arrangement can therefore make repeated use of accurate surfaces If only a n oscillatory movement is required, some additional arrangements can be used in which the geometric layout prevents continuous rotation About a line The movement will be a rotation, and the arrangement can therefore make repeated use of accurate... 6.3(a) gives the general case, and manufacturers publish, in tabular form, their limiting cases A summary of these data is given in Fig 6.4 for cylindrical and flanged bearings in the preferred standard composition and porosities indicated in Table 6.1 Clearly the problem is a continuous one, hence, when dealing with a critical design, aim for U d about unity and avoid the corners of the stepped relationship... attractive In a plane If the movement is a rotation, the arrangement can make repeated use of accurate surfaces If the movement is rotational and oscillatory, some additional arrangements can be used in which the geometric layout prevents continuous rotation If the imovement is a translation one surface must be large and continuous and to be economically attractive must be fairly cheap The smaller moving... load capacity or oil replenishment With flanged bearings add together the duty of the cylindrical and thrust bearing surfaces - 150 100 90 - 80 - 'O- N . close to the optimum. In a sense the objective of this handbook is to make sure that they do not get it wrong. The format of the book is original and has possibly set an example on the presentation. edition of the Tribology Handbook follows the pattern of the original, first published over twenty years ago. It aims to provide instant access to essential information on the performance. carry all the relative movements in machines. Their performance, therefore, makes a critical contribution to the reliability and efiiciency of all machines. Also because they are the local