Tribology Handbook 2 2010 Part 1 docx

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 [...]... MN/m2 Ibf/in2 MN/m’ lbf/inz Tin-base white metal 35 5000 14 20 00 not seized Lead-base white metal 35 5000 14 20 00 not seized 7 013 0 copper-lead, unplated 95 13 500 11 -14 16 00 -20 00 7 013 0 copper-lead, overlay plated 70 11 9 1O OOO overlay 17 000 copperlead -t3) -3 () ( 31 - ( - - 5.5 -1 1 800- 16 00 Lead bronze (22 % lead, 4% tin), overlay plated 70 12 5 1 000 overlay 0 18 000 lead bronze -(3) ( Lead bronze (10 %... bronze -(3) ( Lead bronze (10 % lead, 10 %tin), unplated - - 3-8.5 400- 12 0 0 6% tin-aluminium, unplated 10 5 15 000 5.5 -14 80Cb2000 -(’I -( 31 -( 31 -( 31 Lead bronze (22 % lead, 4% tin), unplated _ ~ 76 11 4 11 000 overlay 16 500 tinaluminium Aluminium-tin-silicon 11 8 13 000 10 -14 Aluminium -20 % tin 90 13 000 14 6% tin-aluminium, overlay plated 3) 3) 15 00 -20 00 20 00 usually - Notes: (1) Fatigue ratings determined on... I I I I 1 1 I I I 'E 50 -2 0 .1 I I , I I 02 0.3 0.5 0 7 I I , in 1 3 4 5 67 2 I , , , , I I l l I 3 E f 2 I1 20 F ! 1 ; - 0.7 - 05 - 0.4 - 0.3 10 7 07 05 04 03 5 1 3 2 4 BORE DIAMETER, m m 5 7 10 20 30 4050 70 10 0 BORE DIAMETER, mrn 02 20 0 (b) (a) BORE DIAMETER, in 0 .2 0.3 0.40.5 07 1 0 .1 c 2 Er 40 $ 30 z w J , - 3 70 - :z , -5 -4 10 0 I : 20 01 8 I (a) BORE DIAMETER, 20 0 I DIAMETER 2 3 4 5... 6 .1 A6 .2 WUI OD2 OOL OL I'O os OP OE ~ 3 i 3 w v i a WOE 02 01 L z 5 t E 1 E'O P'O s o LD -8 rn z i f I 9 '1 E t E a UIW I'O 0 02 0 01 OL OS OP OE ' u ~ i 3 w v i a 311 08 02 01 1 9 P E 1 Lg E'O L P'O 01 SO ' L'O r oz z ' OE f Ob I rn 3 I 5 2 ' E t S 9 8 ! 9 S P E Z 1 L'O s'op'o E'O 2 0 ' 'J! 'M 313 WVIO 3MO8 L'o I 20 0 - s t f Pa3 900 c' 80'0 10 ' 0 n m WnWlNlW u! '383HdS 3 H l A0 t1 313 WVlQ 9V s6ulJeaq 1eJaU.J... linings -0.5 mm (0. 020 in) thick Ibf/in2 10 .3 -13 .7 15 00 -20 00 20 °C Soft journal 40) satisfactory ( -1 > 17 .2 >25 00 As above 70/30 copper-lead on steel 24 -27 .5 3500-4000 -25 0 70/30 copper-lead on steel, overlay plated 27 .5- 31 40004500 -23 0 Lead bronze, 20 -25 % lead, 3-5% tin, on steel 35- 42 5000-6000 -500 42- 52 6000-7500 -23 0 >48 > 7000 -500 Aluminium-6~o ‘solid’ or steel-backed tin, - 42 -6000 -500 kF, above,... static load CO@ ttmp CXP MN/m2 lo3 Ibf/in2 lypc Examplcs Heat conductivity "C 10 61 C W/m"C Spccialfeatures Btu/ft h "F Thermoplastics Nylon, acetal, UHMWPE 10 1. 5 10 0 10 0 0 .24 0 .14 Inexpensive Thermoplastics +fillas Above+MoSz, PTFE, glass, graphite, etc 15 -20 2- 3 15 0 60 -10 0 0 .24 0 .14 Solid lubricants reduce friction Glass, bronze, mica, carbon, metals 2- 7 0.3 -1 25 0 60 -10 0 0 .25 - 0 .15 0.3 Very low friction... Maximum Coejicient $ f Ibf/in2 MN/mZ ibfjin2 xft/min niNim' x rnis tc%p&m "C 20 0-300 1 42 - 4 3000 01 1 350-500 Msterinl Carbon/graphite for continuous operation 5000 friction O.lW .25 dry Cot$cient of expamion x 10 -6/0c 2. 5-5.0 0 .18 450-600 3 -11 4000 0 .14 5 13 0-350 for continuous operation 6000 with metal For continuous dry operation P$ 20 0 Ibf/in2 ( 1. 4 MN/m2), 25 0 ft/min (1 .25 m/s) "4 for short period... -4 10 0 I : 20 01 8 I (a) BORE DIAMETER, 20 0 I DIAMETER 2 3 4 5 6 7 8 ' 2OOr 'Jt BORE DIAMETER, in 0.3 0.40.5 07 1 0 .2 0 .1 I t I I I 2 3 4 5 6 78 I -6 -5 -4 10 0 -3 -2 70 5 r + z a = z W 2 50 40 30 20 10 1. 6mm 7 51 [kir.) I I 2 3 03 7 I I , I , , I 5 _i l 4 5 7 10 20 30 40 50 70 10 0 BORE DIAMETER, m m " 9 1 2 3 7 10 20 30 40 50 70 10 0 BORE DIAMETER, rnm 4 5 (C) (di Wall thickness and concentricity for:... Sn, Pb 3-5 0.450.75 350 45 - 15 -30 9 -18 Strength increased Carbon-metal Metal-solid lubricant Bronze-graphite -MoS, ; Ag- 30-70 4. 510 25 CL 500 10 -20 50 -10 0 3 High temperature capability 350 50 27 5 20 42 24 700 10 0 25 0 12 0 .24 0 .14 50 7.5 15 0 10 0.3 0 .2 7 1 77 5 10 0 0.3 0 .2 0.45 W PTFE Special nonmachinable products Porous bronze/ PTFE/Pb F'TFE/glass weave +resin Thermoset+ PTFE surface Metal+ filled... misleading lo2 10 10 ’ lo2 Curves relate to journal bearings with a wear rate of 25 pm (1 thou.) /10 0 h-unidirectional load; 12 . 5 pm (0.5 thou.) /10 0h-rotating load Counterface finish 0 .2- 0.4 pm cla (8 -16 pin) A Thermoplastics B PTFE C PTFE +fillers D Porous bronze PTFE +Pb E PTFGglass weave+ thermoset F Reinforced thermoset+ MoS, G Thermoset/carbon-graphite +PTFE 10 + 0 .1 0. 01 0. 01 0 .1 1 V, A5 .2 mls 10 A5 Dry . AI .3 A2 Selection of journal bearings 10 000 000 10 00 000 ul c $ 10 0000 m 0 a s z = 10 000 2 < z u n 10 00 10 0 10 00 000 10 0 000 10 000 10 00 10 0 10 10 n, rev/s. cablcs Ihmping dcviccs Pistons Piston rings Cvlinders and lincrs Seals B19 B20 B2 1 B 22 B23 B24 B25 B26 B27 Selection of seals Sealing against dirt and dust Oil flinger rings and. 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 A 12 A13 A14 A15 A16 A17 A18