This article includes a list of general references, but it lacks sufficient corresponding inline citations .(April 2012) |
Spiral groove bearings (also known as Rifle bearings) are self-acting (journal and thrust), or hydrodynamic bearings used to reduce friction and wear without the use of pressurized lubricants. They have this ability due to special patterns of grooves. Spiral groove bearings are self-acting because their own rotation builds up the pressure needed to separate the bearing surfaces. For this reason, they are also contactless bearings.
Spiral groove thrust bearings produce the required pressure to keep the bearing surfaces lubricated and separated purely by the pumping effect of the grooves, whereas journal, conical and spherical forms also get extra pressure generation by the hydrodynamic bearing wedge action. When the parts of the bearings are rotated with respect to each other the grooves push the lubricant through the bearing between the surfaces causing an overall rise in the pressure.
The motion of the surfaces will then cause the fluid to flow over the grooves and a pressure ripple, perpendicular to the direction of the motion, is formed. Between the surface of the bearings and the fluid, a net pressure rise occurs because this flow is limited by a plain bearing section or another set of grooves producing a pressure rise that acts to counter the pressure rise created by the first set of grooves (herringbone pattern). At a sufficient speed, the internal pressures create enough force to support the applied load and the bearing surfaces are completely separated. It is the pressure acting perpendicular to the direction of motion that supports the bearing load.
Most gases or liquids can be used as the lubricant, including refrigerants, liquid metals, oil, grease, [1] water or air. [2]
This explanation neglects the effects of inertia, compressibility of the lubricant and other factors. [3]
The dimensions of the grooves are tailored to the intended operating conditions of the bearing. If the indentations on the grooved surface are too deep, then there will be significant leakage of the lubricant. If the depth is reduced, the pump effect will stop. The speed of the rotation of the bearing surfaces and the accuracy of the dimensions must also be taken into account. Designers and manufactures calculate the optimal dimensions for greatest efficiency. [4] The grooves are made by the following methods:
Etching is easiest way to make spiral groove bearings. The surface of the metal is coated with an etchant-resistant lacquer, then the intended locations of the grooves are removed by hand. The factors that affect the properties of the grooves in this method are:
Despite the simplicity of this method, there is a significant disadvantage: the groove depth is non-uniform and is therefore fairly inaccurate.
This method differs from regular etching as two layers are placed on the surface to be grooved, but only the upper layer is exposed to the etchant, leaving the lower surfaces protected.
This method is used when more accurate and more uniform grooves are required. The grooves are cut by an electrical diameter cutter, The disc surface is rotated, and the cutter it is steered by a guider ring, so that the spirals have the required logarithmic shape.
One disadvantage of this method is that more specialized equipment is required to accurately cut smaller grooves. (approximately 6 cm and less).
Soldering is used when other fabrication methods are unavailable or inapplicable to the given situation; e.g., the bearing is too large for an etching bath. A foil on which the grooves have been etched is obtained, and is soldered onto the flat bearing surface.
The factors that are considered in this method are:
Modern lasers have made the production of precise grooves easier and more affordable, but not all lasers nor laser companies have the required technology. A good supplier will produce precise constant depth grooves in ceramic or metal parts to within fractions of a micrometer, including proper logarithmic grooves for thrust bearings.
These are main types of spiral groove bearings. [5]
Cylindrical form journal bearings with a herringbone pattern of spiral grooves gives a bearing with excellent load capacity, resistance to cavitation and excellent stability.
The symmetric herringbone pattern has zero flow which reduces the possibility of entraining dirt into the bearing, but spiral groove journal bearings are also found with a single pattern that produces a through flow of lubricant. This feature has been used to produce a known volume of flow for constant-flow diesel-pump metering systems.
Flat thrust bearings, the most common spiral groove bearings, are so named because one consists of a flat surface that opposes the grooved surface.
Variations in this type of bearing come from the nature of the spiral surface and the type of fluid flow. The following is a list of the different types of flat thrust bearings:
A spherical (or more usually a hemispherical) thrust bearing consists of a sphere that rotates concentrically in a spherical cup with groove patterns.
The image shows the grease lubricated spiral groove hemispherical bearing invented by Ron Woolley of the Gas Bearing Advisory Service at Southampton University in collaboration with British Gas. [6]
In these bearings, a cone is cut out of the end of a cylindrical shaft. On the surface of the cone next to the cylindrical part, the grooves are made.
Spiral groove bearings were invented in the UK and one of the first published papers was that by Whipple from which they were originally referred to as Whipple grooves. [7] During the 1960s and 1970s there was an explosion in analytic methods for their design and numerous applications were tried. Much of the history can be seen throughout the publications of the International Gas Bearing Symposium [8]
Spiral groove bearings were used most successfully in inertial gyroscopes for planes and ships. [9] In this application, the spiral groove bearings were made of boron carbide ceramic and the grooves were manufactured by ION beam. The bearings were very successful, with MTBF values over 100,000 hours and stop-start capability of 1,000,000 times. [10]
Due to the multiple technical advantages, thrust bearings continue to be used in gyroscopes such as in the Hubble Telescope. [11]
Many other applications have arisen over the last 20 years in compressors and turbines taking advantage of the oil-free, long life, low friction and clean green characteristics. [12]
One major application area is that of the dry gas seal where a spiral groove thrust bearing acts to lift the seal faces apart creating a narrow seal gap that prevents contact and wear. These are very successful and have been applied to many industrial compressors.
Another notable use of spiral groove bearings is in cryogenic expanders. They are used here to support the high speed rotation of turbines, and to minimize power losses due to inefficiency. Cryogenic expanders extract energy from the streams of gases that enter it, causing a rapid decrease in temperature, and the energy extracted is used to rotate the turbines. [13] [14]
The following lists the advantages of using spiral groove bearings as opposed to other self-acting bearings.
There are some spreadsheet design methods on the market for incompressible lubricants (oil, water), but for compressible gas lubricants one has to resort to numerical methods and specialist design companies. Generally the analysis of spiral groove bearings requires a numerical method solving the Reynolds Equation although there are some optimum parameters published. [15] Modern CFD methods are not suitable for general design work as the number of elements around the bearing and across the clearance makes the analyses too slow. The critical design aspect for all bearings using compressible gas lubricants is stability whereas for in-compressible fluids load and power loss become equally important.
A lubricant is a substance that helps to reduce friction between surfaces in mutual contact, which ultimately reduces the heat generated when the surfaces move. It may also have the function of transmitting forces, transporting foreign particles, or heating or cooling the surfaces. The property of reducing friction is known as lubricity.
The turbojet is an airbreathing jet engine which is typically used in aircraft. It consists of a gas turbine with a propelling nozzle. The gas turbine has an air inlet which includes inlet guide vanes, a compressor, a combustion chamber, and a turbine. The compressed air from the compressor is heated by burning fuel in the combustion chamber and then allowed to expand through the turbine. The turbine exhaust is then expanded in the propelling nozzle where it is accelerated to high speed to provide thrust. Two engineers, Frank Whittle in the United Kingdom and Hans von Ohain in Germany, developed the concept independently into practical engines during the late 1930s.
A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation between the bearing races.
Fluid bearings are bearings in which the load is supported by a thin layer of rapidly moving pressurized liquid or gas between the bearing surfaces. Since there is no contact between the moving parts, there is no sliding friction, allowing fluid bearings to have lower friction, wear and vibration than many other types of bearings. Thus, it is possible for some fluid bearings to have near-zero wear if operated correctly.
A bearing is a machine element that constrains relative motion to only the desired motion and reduces friction between moving parts. The design of the bearing may, for example, provide for free linear movement of the moving part or for free rotation around a fixed axis; or, it may prevent a motion by controlling the vectors of normal forces that bear on the moving parts. Most bearings facilitate the desired motion by minimizing friction. Bearings are classified broadly according to the type of operation, the motions allowed, or the directions of the loads (forces) applied to the parts.
Lubrication is the process or technique of using a lubricant to reduce friction and wear and tear in a contact between two surfaces. The study of lubrication is a discipline in the field of tribology.
A compressor is a mechanical device that increases the pressure of a gas by reducing its volume. An air compressor is a specific type of gas compressor.
A diving air compressor is a breathing air compressor that can provide breathing air directly to a surface-supplied diver, or fill diving cylinders with high-pressure air pure enough to be used as a hyperbaric breathing gas. A low pressure diving air compressor usually has a delivery pressure of up to 30 bar, which is regulated to suit the depth of the dive. A high pressure diving compressor has a delivery pressure which is usually over 150 bar, and is commonly between 200 and 300 bar. The pressure is limited by an overpressure valve which may be adjustable.
A magnetic bearing is a type of bearing that supports a load using magnetic levitation. Magnetic bearings support moving parts without physical contact. For instance, they are able to levitate a rotating shaft and permit relative motion with very low friction and no mechanical wear. Magnetic bearings support the highest speeds of any kind of bearing and have no maximum relative speed.
A plain bearing, or more commonly sliding contact bearing and slide bearing, is the simplest type of bearing, comprising just a bearing surface and no rolling elements. Therefore, the journal slides over the bearing surface. The simplest example of a plain bearing is a shaft rotating in a hole. A simple linear bearing can be a pair of flat surfaces designed to allow motion; e.g., a drawer and the slides it rests on or the ways on the bed of a lathe.
A jewel bearing is a plain bearing in which a metal spindle turns in a jewel-lined pivot hole. The hole is typically shaped like a torus and is slightly larger than the shaft diameter. The jewels are typically made from the mineral corundum, usually either synthetic sapphire or synthetic ruby. Jewel bearings are used in precision instruments where low friction, long life, and dimensional accuracy are important. Their main use is in mechanical watches.
In mechanical engineering, a rolling-element bearing, also known as a rolling bearing, is a bearing which carries a load by placing rolling elements between two concentric, grooved rings called races. The relative motion of the races causes the rolling elements to roll with very little rolling resistance and with little sliding.
Anthony George Maldon Michell FRS was an Australian mechanical engineer of the early 20th century.
The Stribeck curve is a fundamental concept in the field of tribology. It shows that friction in fluid-lubricated contacts is a non-linear function of the contact load, the lubricant viscosity and the lubricant entrainment speed. The discovery and underlying research is usually attributed to Richard Stribeck and Mayo D. Hersey, who studied friction in journal bearings for railway wagon applications during the first half of the 20th century; however, other researchers have arrived at similar conclusions before. The mechanisms along the Stribeck curve have been in parts also understood today on the atomistic level.
Dry lubricants or solid lubricants are materials that, despite being in the solid phase, are able to reduce friction between two surfaces sliding against each other without the need for a liquid oil medium.
Albert Kingsbury was an American engineer, inventor and entrepreneur. He was responsible for over fifty patents obtained between the years 1902 to 1930. Kingsbury is most famous for his hydrodynamic thrust bearing which uses a thin film of oil to support weights of up to 220 tons. This bearing extended the service life of many types of machinery during the early 20th century. It was primarily outfitted on Navy ships during World War I and World War II.
This article briefly describes the components and systems found in jet engines.
In fluid mechanics, the Reynolds equation is a partial differential equation governing the pressure distribution of thin viscous fluid films. It was first derived by Osborne Reynolds in 1886. The classical Reynolds Equation can be used to describe the pressure distribution in nearly any type of fluid film bearing; a bearing type in which the bounding bodies are fully separated by a thin layer of liquid or gas.
Air bearings are bearings that use a thin film of pressurized gas to provide a low friction load-bearing interface between surfaces. The two surfaces do not touch, thus avoiding the traditional bearing-related problems of friction, wear, particulates, and lubricant handling, and offer distinct advantages in precision positioning, such as lacking backlash and static friction, as well as in high-speed applications. Space craft simulators now most often use air bearings and 3-D printers are now used to make air-bearing-based attitude simulators for CubeSat satellites.
An internal combustion engine is a heat engine in which the combustion of a fuel occurs with an oxidizer in a combustion chamber that is an integral part of the working fluid flow circuit. In an internal combustion engine, the expansion of the high-temperature and high-pressure gases produced by combustion applies direct force to some component of the engine. The force is typically applied to pistons, turbine blades, a rotor, or a nozzle. This force moves the component over a distance, transforming chemical energy into kinetic energy which is used to propel, move or power whatever the engine is attached to.
{{cite journal}}
: Cite journal requires |journal=
(help){{cite journal}}
: Cite journal requires |journal=
(help)