Abstract: The health of the journal bearings is very important in preventing unforeseen breakdowns in rotary machines, and poor lubrication is one of the most important factors for producing the bearing failures. Hydrodynamic lubrication (HL), mixed lubrication (ML), and boundary lubrication (BL) are three regimes of a journal bearing lubrication. This paper uses acoustic emission (AE) measurement technique to correlate features of the AE signals to the three lubrication regimes. The transitions from HL to ML based on operating factors such as rotating speed, load, inlet oil pressure by time domain and time-frequency domain signal analysis techniques are detected, and then metal-to-metal contacts between sliding surfaces of the journal and bearing are identified. It is found that there is a significant difference between theoretical and experimental operating values that are obtained for defining the lubrication regions.
Abstract: This paper presents a numerical analysis for the dynamic performance of a finite journal bearing lubricated with couple stress fluid taking into account the effect of the deformation of the bearing liner. The modified Reynolds equation has been solved by using finite difference technique. The dynamic characteristics in terms of stiffness coefficients, damping coefficients, critical mass and whirl ratio are evaluated for different values of eccentricity ratio and elastic coefficient for a journal bearing lubricated with a couple stress fluids and a Newtonian fluid. The results show that the dynamic characteristics of journal bearings lubricated with couple stress fluids are improved compared to journal bearings lubricated with Newtonian fluids.
Abstract: Centrifugal-casting machine is used in manufacturing
special machine components like multi-layer journal bearing used in
all internal combustion engine, steam, gas turbine and air craft turboengine
where isotropic properties and high precisions are desired.
Moreover, this machine can be used in manufacturing thin wall hightech
machine components like cylinder liners and piston rings of IC
engine and other machine parts like sleeves, and bushes. Heavy-duty
machine component like railway wheel can also be prepared by
centrifugal casting. A lot of technological developments are required
in casting process for production of good casted machine body and
machine parts. Usually defects like blowholes, surface roughness,
chilled surface etc. are found in sand casted machine parts. But these
can be removed by centrifugal casting machine using rotating
metallic die. Moreover, die rotation, its temperature control, and good
pouring practice can contribute to the quality of casting because of
the fact that the soundness of a casting in large part depends upon
how the metal enters into the mold or dies and solidifies. Poor
pouring practice leads to variety of casting defects such as
temperature loss, low quality casting, excessive turbulence, over
pouring etc. Besides these, handling of molten metal is very
unsecured and dangerous for the workers. In order to get rid of all
these problems, the need of an automatic pouring device arises. In
this research work, a robot assisted pouring device and a centrifugal
casting machine are designed, developed constructed and tested
experimentally which are found to work satisfactorily. The robot
assisted pouring device is further modified and developed for using it
in actual metal casting process. Lot of settings and tests are required
to control the system and ultimately it can be used in automation of
centrifugal casting machine to produce high-tech machine parts with
desired precision.
Abstract: Journal bearings used in IC engines are prone to premature
failures and are likely to fail earlier than the rated life due to
highly impulsive and unstable operating conditions and frequent
starts/stops. Vibration signature extraction and wear debris analysis
techniques are prevalent in industry for condition monitoring of
rotary machinery. However, both techniques involve a great deal of
technical expertise, time, and cost. Limited literature is available on
the application of these techniques for fault detection in reciprocating
machinery, due to the complex nature of impact forces that
confounds the extraction of fault signals for vibration-based analysis
and wear prediction. In present study, a simulation model was developed to investigate
the bearing wear behaviour, resulting because of different operating
conditions, to complement the vibration analysis. In current
simulation, the dynamics of the engine was established first, based on
which the hydrodynamic journal bearing forces were evaluated by
numerical solution of the Reynold’s equation. In addition, the
essential outputs of interest in this study, critical to determine wear
rates are the tangential velocity and oil film thickness between the
journals and bearing sleeve, which if not maintained appropriately,
have a detrimental effect on the bearing performance. Archard’s wear prediction model was used in the simulation to
calculate the wear rate of bearings with specific location information
as all determinative parameters were obtained with reference to crank
rotation. Oil film thickness obtained from the model was used as a
criterion to determine if the lubrication is sufficient to prevent contact
between the journal and bearing thus causing accelerated wear. A
limiting value of 1 μm was used as the minimum oil film thickness
needed to prevent contact. The increased wear rate with growing
severity of operating conditions is analogous and comparable to the
rise in amplitude of the squared envelope of the referenced vibration
signals. Thus on one hand, the developed model demonstrated its
capability to explain wear behaviour and on the other hand it also
helps to establish a co-relation between wear based and vibration
based analysis. Therefore, the model provides a cost effective and
quick approach to predict the impending wear in IC engine bearings
under various operating conditions.
Abstract: The article presents two mathematical models of the
interaction between a rotating shaft and an incompressible fluid. The
mathematical model includes both the journal bearings and the
axially traversed hydrodynamic sealing gaps of hydraulic machines.
A method is shown for the identification of additional effects of the
fluid acting on the rotor of the machine, both for a linear and a nonlinear
model. The interaction is expressed by matrices of mass,
stiffness and damping.
Abstract: Fixed-geometry hydrodynamic journal bearings are
one of the best supporting systems for several applications of rotating
machinery. Cylindrical journal bearings present excellent loadcarrying
capacity and low manufacturing costs, but they are subjected
to the oil-film instability at high speeds. An attempt of overcoming
this instability problem has been the development of non-circular
journal bearings. This work deals with an analysis of oil-lubricated
elliptical journal bearings using the finite element method. Steadystate
and dynamic performance characteristics of elliptical bearings
are rendered by zeroth- and first-order lubrication equations obtained
through a linearized perturbation method applied on the classical
Reynolds equation. Four-node isoparametric rectangular finite
elements are employed to model the bearing thin film flow. Curves of
elliptical bearing load capacity and dynamic force coefficients are
rendered at several operating conditions. The results presented in this
work demonstrate the influence of the bearing ellipticity on its
performance at different loading conditions.
Abstract: In this paper, the dynamic characteristics of a threelobe
journal bearing lubricated with micropolar fluids are determined
by the linear stability theory. Lubricating oil containing additives and
contaminants is modelled as micropolar fluid. The modified
Reynolds equation is obtained using the micropolar lubrication theory
.The finite difference technique has been used to determine the
solution of the modified Reynolds equation. The dynamic
characteristics in terms of stiffness, damping coefficients, the critical
mass and whirl ratio are determined for various values of size of
material characteristic length and the coupling number. The
computed results show that the three-lobe bearing lubricated with
micropolar fluid exhibits better stability compared with that
lubricated with Newtonian fluid. According to the results obtained,
the effect of the parameter micropolar fluid is remarkable on the
dynamic characteristics and stability of the three-lobe bearing.
Abstract: Load carrying capacity of an oil lubricated two-axial
groove journal bearing is simulated by taking into account the
viscosity variations in lubricant due to the addition of TiO2
nanoparticles as lubricant additive. Shear viscosities of TiO2
nanoparticle dispersions in oil are measured for various nanoparticle
additive concentrations. The viscosity model derived from the
experimental viscosities is employed in a modified Reynolds
equation to obtain the pressure profiles and load carrying capacity of
two-axial groove journal bearing. Results reveal an increase in load
carrying capacity of bearings operating on nanoparticle dispersions as
compared to plain oil.
Abstract: The study deals with the challenges in developing a
test rig to test the performance of water lubricated journal bearing.
The test rig is designed to simulate the working conditions of the
bearing in order to understand their performance before they are put
in operation. The bearing that is studied is the commercially available
water lubricated bearing which has a rubber liner bonded with a rigid
metal shell. The lubricant enters the bearing axially through a
pressurized inlet tank and exits to an outlet tank which is at
sufficiently low pressure. The load on the bearing is applied through
the dead weight system which acts both in upward and downward
direction so that net load acts on the bearing. The issues in feeding
the lubricant into the bearing from the inlet side and preventing the
leakage of the lubricant is discussed. The application of the load on
the test bearing while maintaining the bearing afloat is also discussed.
Abstract: Vibration monitoring methods of most critical equipment like main turbine and compressors always plays important role in preventive maintenance and management consideration in big industrial plants. There are a number of traditional methods like monitoring the overall vibration data from Bently Nevada panel and the time wave form (TWF) or fast Fourier transform (FFT) monitoring. Besides, Shaft centerline monitoring method developed too much in recent years. There are a number of arguments both in favor of and against this method between people who work in preventive maintenance and condition monitoring systems (vibration analysts). In this paper basic principal of Turbine compressor vibration analysis and rotor movement evaluation by shaft centerline method discussed in details through a case history. This case history is related to main turbine compressor of an olefin plant in Iran oil industry. In addition, some common mistakes that may occur by vibration analyst during the process discussed in details. It is worthy to know that, these mistakes may one of the reasons that sometimes this method seems to be not effective. Furthermore, recent patent and innovation in shaft position and movement evaluation are discussed in this paper.
Abstract: The work described in this paper is an investigation of the static and dynamic characteristics of two-lobe journal bearings taking into consideration the thermal effects. A thermo-hydrodynamic solution of a finite two-lobe journal bearing is performed by solving the generalized form Reynolds equation with the energy equation, taking into consideration viscosity variation across the film thickness. The static and dynamic characteristics were numerically obtained. The results are evaluated for different values of viscosity-temperature coefficient and Peclet number. The results show that considering the thermal effects in the solution of the two-lobe journal bearing has a marked on the study of its stability.
Abstract: The objective of the present paper is to theoretically investigate the steady-state performance characteristics of journal bearing of finite width, operating with micropolar lubricant in a turbulent regime. In this analysis, the turbulent shear stress coefficients are used based on the Constantinescu’s turbulent model suggested by Taylor and Dowson with the assumption of parallel and inertia-less flow. The numerical solution of the modified Reynolds equation has yielded the distribution of film pressure which determines the static performance characteristics in terms of load capacity, attitude angle, end flow rate and frictional parameter at various values of eccentricity ratio, non-dimensional characteristics length, coupling number and Reynolds number.
Abstract: A theoretical investigation on the effects of both
steady-state and dynamic deformations of the foils on the dynamic
performance characteristics of a self-acting air foil journal bearing
operating under small harmonic vibrations is proposed. To take into
account the dynamic deformations of foils, the perturbation method is
used for determining the gas-film stiffness and damping coefficients
for given values of excitation frequency, compressibility number, and
compliance factor of the bump foil. The nonlinear stationary
Reynolds’ equation is solved by means of the Galerkins’ finite
element formulation while the finite differences method are used to
solve the first order complex dynamic equations resulting from the
perturbation of the nonlinear transient compressible Reynolds’
equation. The stiffness of a bump is uniformly distributed throughout
the bearing surface (generation I bearing). It was found that the
dynamic properties of the compliant finite length journal bearing are
significantly affected by the compliance of foils especially whenthe
dynamic deformation of foils is considered in addition to the static
one by applying the principle of superposition.
Abstract: This paper presents the mathematical description of the high-speed rotating system taking into account the influence of internal and external damping. The mathematical model is obtained by using the finite element method. The analyzed system is an automotive turbocharger understood as a rotor-bearing system. The circular cross-section shaft is equipped with one compressor wheel, one turbine wheel and is supported by two floating ring bearings. Based on the model, the dynamical analysis of a turbocharger is performed and stability conditions are evaluated.
Abstract: The stability characteristics of water lubricated journal bearings having three axial grooves are obtained theoretically. In this lubricant (water) is fed under pressure from one end of the bearing, through the 3-axial grooves (groove angles may vary). These bearings can use the process fluid as the lubricant, as in the case of feed water pumps. The Reynolds equation is solved numerically by the finite difference method satisfying the boundary conditions. The stiffness and damping coefficient for various bearing number and eccentricity ratios, assuming linear pressure drop along the groove, shows that smaller groove angles better results.
Abstract: The aim of the paper work is to investigate and predict
the static performance of journal bearing in turbulent flow condition
considering micropolar lubrication. The Reynolds equation has been
modified considering turbulent micropolar lubrication and is solved
for steady state operations. The Constantinescu-s turbulence model is
adopted using the coefficients. The analysis has been done for a
parallel and inertia less flow. Load capacity and friction factor have
been evaluated for various operating parameters.
Abstract: This paper presents a numerical approach for the static
and dynamic analysis of hydrodynamic radial journal bearings. In the
first part, the effect of shaft and housing deformability on pressure
distribution within oil film is investigated. An iterative algorithm that
couples Reynolds equation with a plane finite elements (FE)
structural model is solved. Viscosity-to-pressure dependency (Vogel-
Barus equation) is also included. The deformed lubrication gap and
the overall stress state are obtained. Numerical results are presented
with reference to a typical journal bearing configuration at two
different inlet oil temperatures. Obtained results show the great
influence of bearing components structural deformation on oil
pressure distribution, compared with results for ideally rigid
components. In the second part, a numerical approach based on
perturbation method is used to compute stiffness and damping
matrices, which characterize the journal bearing dynamic behavior.
Abstract: This research details a Computational Fluid Dynamics (CFD) approach to model fluid flow in a journal bearing with 8 equispaced semi-circular axial grooves. Water is used as the lubricant and is fed from one end of the bearing to the other, under pressure. The geometry of the bearing is modeled using a commercially available modeling software GAMBIT and the flow analysis is performed using a dedicated CFD analysis software FLUENT. The pressure distribution in the bearing clearance is obtained from FLUENT for various whirl ratios and is used to calculate the hydrodynamic force components in the radial and tangential direction of the bearing. These values along with the various whirl speeds can be used to do a regression analysis to determine the stiffness and damping coefficients. The values obtained are then compared with the stiffness and damping coefficients of a 3 Axial groove water lubricated journal bearing and those obtained from a FORTRAN code for a similar bearing.
Abstract: Dynamic characteristics of a four-lobe journal bearing
of micropolar fluids are presented. Lubricating oil containing
additives and contaminants is modelled as micropolar fluid. The
modified Reynolds equation is obtained using the micropolar
lubrication theory and solving it by using finite difference technique.
The dynamic characteristics in terms of stiffness, damping
coefficients, the critical mass and whirl ratio are determined for
various values of size of material characteristic length and the
coupling number. The results show compared with Newtonian fluids,
that micropolar fluid exhibits better stability.