Lecture 07 Bearings

2.
72
Elements of
Mechanical Design

Lecture 07: Rolling
contact bearings
2 Martin Culpepper, All rights reserved
Schedule and reading assignment
Quiz
Constraints

Topics
Bearing types & failure modes
Experimental results to modeling
Bearing load-life-reliability
Start spindle exercise

Reading assignment
None, work on getting bearings done

Quiz Tuesday
Bearings (conceptual)
www.renault4.co.uk/
Besides the childrens toy (sorry bout that), what do
you notice about the bearing that should be of import?
Loose ends
Thermal stability
Function of separation distance and contact geometry - cancellation
Will you always have bearing death if it is not thermally stable?

Mounting of races: Inside rotating vs. outside rotating
Friction torques
Look at the tapered roller example from lab
T
R
T
q
A
=
cross
Cond T
A k
t
R =
surface
Conv T
A h
R
1
=

Rough design steps Inherently iterative
Step 1: Functional requirements
DOF
Stiffness
Lifetime/reliability
Etc

Step 2: Bearing type/layout

Step 3: System design & mfg issues
Housing geometry Shaft geometry
Shaft deflection Preload
Thermal Tolerances

Step 4: Assembly specifications
Iteration

Types of rolling contact
bearings
Examples of rolling element bearings
static.howstuffworks.com
www.machinedesign.com
www.gm-exports.com/
www.bearingsworld.com
Inner
Ring Race

Outer
Ring Race

Diameters
Outer Bore

Ball/roller

Cage/separator

Face

Width
Elements: Rotary rolling contact bearing

Bearing failure:
Causes and
failure mode
Brinelling plus cracks
www.amstedrail.com
Subsurface face fatigue crack that has progressed
to surface. Magnification 100X
Cracks in bearings elements
Brinelling of surface
Failure mode: Spalling
http://www.tsb.gc.ca
Causes of spalling
Spalling
Surface fatigue that occurs as a result of contact

Seeds of failure
Crack growth
Inclusions
Impact
Cyclic high stress
Degradation of the lubricant

Once it starts, what happens?
Minor spalling + correct problem may slow/stop
Typically increases in size with continued service
Steel quality key to
making long-lasting
bearings

Preload
Model ball-groove contacts as six balls on flats

Important relationships for ball-flat contact
Ball-flat elastomechanics: Hertz contact
1 1
2 2
2
n e
k R E o =
F
Hertzian contacts
act as non-linear
springs
Hertz
1857-1894
o
Location, magnitude of max shear stress
Max t

Max shear stress occurs below
surface, in the member with
largest R if ball and flat of same
material
3
1
2
2
48 . 0
max
6 1
31 . 0
|
|
.
|
\
|

=
=
e
e
contact of center
radius contact depth
R
E F
t
t
or major or major
e
R R R R
R
min 2 2 min 1 1
1 1 1 1
1
+ + +
=
2
2
2
1
2
1
1 1
1
E E
E
e
q q
+
=
Equivalent modulus
Equivalent radius
Preload increases stiffness

A little preload goes a long way

Classes of preload, as % of static load capacity
Heavy 5%
Medium 3%
Light 2%
Sensitivity of contact stiffness to AF
3
1
3
2
3
1
o
K
n e e n
F E R k
|
.
|
\
|
=
Contact stiffness
0
05
10
20
30
0 250 500 750 1000
Fn [N]
k

[
N
/
m
i
c
r
o
n
]
Large Ak for small APreload
How do you preload a bearing?
Direct
Nuts pressing directly on races
Uses compliance of contacts

Internal
Oversized balls
Uses compliance of ball-race contacts

Nuts-springs
Spring in series with bearing
Primarily uses compliance of spring

Think in terms of relative stiffness because
Sensitivity of force to the displacement
Many bearings come
preloaded out of the box

Check to make sure so that
you do not add preload that
will act to overload

Bearing life and
reliability
Bearing life depends on:
Load and revolutions

From experimentation: For a given R, linear log behavior
Reliability = % chance that the part will function as expected

Where
a = 3 for ball bearings
a = 3.333 for roller bearings
Bearing life at rated reliability
=
a
L F
1
log(F)
log(L)
Regression fit to experimental data
Manufacturers provide a match of:
Cycle rating: Revolutions For example 10
6
or 90
6
revs
Load rating: Force Anything

that defines bearing failure for a given reliability

Given these two numbers, and:

This may be used to extrapolate behavior at different
loads and revs
design
a
design
i
a
i
L F L C
1 1
=
=
a
L F
1
Units of force
Constant
Units of revolutions
Why C vs. F?
This is for common
reliability
Design life in terms of hours or revolutions?
We can think in terms of life as time if:

| | L
hr
rev
hr t =
(
min
60
min
e
( )
a
design
design
a
design
a
t F L F L C
1
1
1
10 10
60 e = =
( ) ( )
a
design design design
a
rated rated
t F t C
1 1
10
60 60 e e =
( )
( )
a
rated rated
a
design design
design
t
t
F C
1
1
10
60
60
e
e
=
Dynamic
load
rating
Revs at failure
Be careful with units
Reliability vs. life
Reliability often well-predicted via Weibull distribution
x
o
= minimum guaranteed value of x
= corresponds to 63.2 percentile of the variate (stochastic variable)
b = a shape parameter (controls skew, large = right)

For bearings, we use this as:

10
L
L
x =
( )
(
(
|
|
.
|
\
|
=
b
o
o
x
x x
x R
u
exp
r(x)
x
x
o
Commonly used to fit experimental
data; b & u come from fit
This is for common
load on bearings
BUT the catalogue never tells me what happens for.
My exact desired load
My exact desired life
Situations when I want a reliability that is different than R = 0.90

C
10
x

Design
R = 0.90
Relationship between load, life and reliability
PF
L
L
x =
log(x)
log(F)
A
D
B
2
1
a
D D
a
B B
x F x F
1 1
: y reliabilit Constant
= =
1
( )
(
(
|
|
.
|
\
|
=
b
o
o B
x
x x
x R
u
exp
load Constant
2
Relationship between load, life and reliability
Load as a function of reliability & vice versa for given:
C
10
L
10
R = 0.90; x = 1 when L = L
10

( )
a
b
D
O O
D
D
R
x x
x
F C
1
1
10
1
ln
(
(
(
(
(
(
|
|
.
|
\
|
+
=
u
C
10
x

Design
R = 0.90
PF
L
L
x =
log(x)
log(F)
A
D
Reliability of multi-bearing sets
What is the reliability of:
One bearing?
A spindle with two bearings?
With N bearings?

For first order design, how should individual bearing
reliability scale as a function of N?
How to handle combined loading
So far we have only considered radial loading

What about combined radial, Fr, and axial loading , Fa?
Use an equivalent load, Fe, that does the same amount of damage.

Where V = 1.2 for outer ring rotation and 1 for inner ring
This has to do with the fact that outer ring fails more often

X
i
and Y
i
are a function of the
Axial load, Fa
Static load rating, Co
a i r i e
F Y F V X F + =
Other issues, Shigley/Mischke covers well
Life recommendations (hrs)
Aircraft engines 0 500 2 000
24-hour critical service 100 000 200 000

Application factors
General commercial 1.1 1.3
Moderate impact 1.5 3.0

Group exercise
Work on your spindle housing-shaft-bearing design
Constraint layout
Loads
Preload
Thermal stability
Cost

Lecture 07 Bearings

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4 Martin Culpepper, All rights reserved

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