BASICS OF MACHINE DESIGN
Machine Design :
It is defined as the use of scientific principles,
Technical informations,
and imagination
in the description of a machine or mechanical system,
to perform specific functions with maximum economy and
efficiency.
Design is an innovative and highly iterative process.
A designer uses principles of basic engineering sciences such as
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physics, mathematics, statics, dynamics, thermodynamics, heat
BEARINGS
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Bearings are machine elements which are used to support a rotating
member viz., a shaft.
They transmit the load from a rotating member to a stationary member
known as frame or housing.
They allow relative motion between two members in one or two directions
with minimum friction, and also prevent the motion in the direction of the
applied load.
Bearings support a shaft or an axle and holds them in correct positions.
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Classification of Bearings
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According to direction of force;
1. Radial Bearing
2. Thrust Bearing
According to type of friction or contact :
1. Sliding Contact( Journal)
2. Rolling Contact( Antifriction)
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Advantages of Sliding Contact Bearings
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Sliding contact bearings have certain advantages over the rolling
contact bearings. These are:
1. Design of the bearing and housing is simple.
2. Occupy less radial space and are more compact.
3. Less expensive
4. Design of the shaft is simple.
5. Silent operation.
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SLIDING CONTACT BEARINGS
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The sliding contact bearings having surface contact and are coming
under lower kinematic pair.
Based on the type of contact between the rotating and the stationary
members, Sliding contact bearings may be broadly classified into
following two categories:
1. Sliding Contact( Journal)
Surface of the shaft slides over the surface of bush
2. Rolling Contact( Antifriction)
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Applications of Sliding Contact Bearings
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Crankshaft bearings in petrol and diesel engines
Centrifugal pumps
Large size electric motors
Steam and gas Turbines,concrete mixture, Rope conveyor and marine
installations
Rolling contact
Automobile front and rear axles, machine tool spindles, Gear boxes
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Disadvantages of Sliding Contact Bearings
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1. Frictional power loss is more.
2. Require good attention to lubrication.
3. Normally designed to carry radial load or axial load only.
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Classification of Sliding Contact Bearings
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Classified in three ways.
1. Based on type of load carried
2. Based on type of lubrication
3. Based on lubrication mechanism
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1. Classification based on Type of load
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Based on the type of load carried, sliding contact bearings may be
classified into the following categories:
a. Radial bearings
b. Thrust bearings or axial bearings
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2. Classification based on Type of Lubrication
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Lubrication
The objective of lubrication is to reduce friction wear and heating of machine
parts that move relative to each other.
A Lubricant is a substance that when inserted between the moving surfaces,
accomplishes theses purposes.
Type of lubrication means the extent to which the contacting surfaces are
separated in a shaft bearing combination.
Based on the type of lubrication, sliding contact bearings may be classified
into the following categories:
(a) Thick film lubrication
(b) Thin film lubrication
(c)
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Boundary lubrication
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…
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Based on the type of lubrication, sliding contact bearings may be classified into
the following categories:
(a) Thick film lubrication
(b) Thin film lubrication
(c) Boundary lubrication
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Types of lubricated Bearings
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Thick film lubrication – the surfaces are separated by thick film of lubricant and there will not be any
metal-to-metal contact. The film thickness is anywhere from 8 to 20 μm. Hydrodynamic lubrication.
Thin film lubrication – Here even though the surfaces are separated by thin film of lubricant, at some
high spots Metal-to-metal contact does exist, it also known as mixed film lubrication. Surface
wear is mild. The coefficient of friction commonly ranges from 0.004 to 0.10.
Boundary lubrication – Here the surface contact is continuous and extensive. The lubricant is
continuously smeared over the surfaces and provides a continuously renewed adsorbed surface film
which reduces the friction and wear. The typical coefficient of friction is 0.05 to 0.20.
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3. Classification based on Lubrication Mechanism
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a. Hydrodynamic lubricated bearings:
Separated by relatively thick film, no metal to metal contact, no
external agency is required for pressure built up
b. Hydrostatic lubricated bearings :
Lubricant is introduced at a pressure high enough to separate the
surfaces
c. Elastohydrodynamic lubricated bearings
d. Boundary lubricated bearings
e. Solid film lubricated bearings
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Hydrodynamic lubrication
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Also called full-film, or fluid lubrication has following characteristics:
The load-carrying surfaces of the bearing are separated by a thick film of
lubricant.
Requires an adequate supply of lubricant at all times.
Does not require introduction of the lubricant under pressure.
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Hydrodynamic lubrication
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Initially the loaded journal bearing is at rest.
The bearing clearance space is filled with oil.
The load (W) has squeezed out the oil film at the bottom.
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Hydrodynamic lubrication
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The shaft starts Slow clockwise rotation.
This will cause it to roll to the right position as it tries to “climb the wall” of the bearing surface. .
Continuous slow rotation would cause the shaft to stay in this position.
The result is the boundary
lubrication.
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Hydrodynamic lubrication
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As the shaft rotating speed is increased, more and more oil goes into the contact zone.
Finally a speed is reached at which the pressure built up in the contact zone is high enough to “float”
the shaft.
Under suitable conditions full separation of the journal and bearing surfaces occurs.
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Hydrodynamic lubricated Bearings
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• In these bearings the load-carrying surfaces are separated by a stable thick film of lubricant that prevents
the metal-to-metal contact.
• The film pressure generated by moving surfaces that force the lubricant through a wedge shaped zone.
• At sufficiently high speed the pressure developed around the journal sustains the load.
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Hydrostatic Lubrication
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In these bearings, externally pressurized lubricant is fed into the bearings to separate the
surfaces with thick film of lubricant.
These types of bearings do not require the motion of the surfaces to generate the lubricant film.
Hence they can operate from very low speed to high speed.
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Elastohydrodynamic Lubricated bearings.
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Rolling contact bearings come under this category. The oil film thickness is very small.
The contact pressures are going to be very high. Hence to prevent the metal-to-metal contact,
surface finishes are to be of high quality.
Such a type of lubrication can be seen in
Gears,
Rolling contact bearings,
Cams etc.
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