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CFD ANALYSIS ONEPOXY FILLED WITH GLASS FIBER/ALUMINIUM OXIDE
SILICON CARBIDE COMPOSITE JOURNAL BEARING
T. Narendiranath Babu*1 D. Rama Prabha2
1
School of Mechanical Engineering, VIT University, Vellore, Tamil Nadu, India.
2
School of Electrical Engineering, VIT University, Vellore, Tamil Nadu, India.
Email: narendiranathbabu.t@vit.ac.in
Received on 09-08-2016 Accepted on 05-09-2016
Abstract
Journal bearings are widely used to support the shaft of industrial machinery with heavy loads, such as compressors,
turbines and centrifugal pumps. The main objective of this study is to explore the design possibility of a journal
bearing and to carry out flow analysis using ANSYS. The main aim is to design a journal bearing with two different
materials and compare the results of the analysis experimentally. The use of fillers and glass fibres has also been reported
to be very effective in reducing wear under adhesive conditions. The reactions of fillers with counter steel surface
contributed to the formation of a thin, stable and adherent transfer film, resulting in lower coefficient of friction and in turn
higher wear resistance. Hence, in these research work the addition of Al2O3 and SiC as a filler material in glass fibre system
has been taken up for investigation from the point of characterizing them for friction and wear behaviour.For this purpose a
full journal bearing is considered. In order to apply forces, divide the bearing hole into equal parts and then apply the
pressure on each part as per the calculated value. The empirical values will be simulated in ANSYS and checked for
accuracy.
1. Introduction
The journal bearings used to provide support and relative motion between rotor systems. They are also the source of
bearing stiffness, damping, and mass properties in rotor bearing systems. The proper design of these bearings is
required for the successful industrial operation of rotating machinery. As machine speeds and loads and instability
drivers increase, there is an increasing need for more accurate fluid film bearing identification carried out for the high
The support forces and dynamic properties in fluid film bearings arise from the fluid-structure interaction forces
iso viscous fluid model. More advanced, modern bearing theories have been developed, including THD and TEHD
bearing models which describe bearing hydrodynamics with significant heating of the lubricant and elastic
deformations of the bearing solid components[1]. Lubricants tarvation effects and turbulence must be accurately
modeled[1]. The models within creased complexity are required to provide more accurate theoretical bearing
parameters, as test data is quite limited. The stiffness, damping, and mass coefficients arise from a perturbation
solution to the elasto hydrodynamic and thermal equations of the model used. However, there is model sensitivity to
design parameters such as bearing clearances, changes in viscosity, manufacturing tolerances, thermal growth, and
Generally, two distinct approaches to exciting the rotor-bearing system for dynamic coefficient identification have been
used. One approach, that resembles real machine operation, involves holding the bearing housing rigidly while exciting
a moving shaft. The other approach, referred in this work as the inverse method, holds the shaft rigidly while exciting the
moving bearing housing. For lubricant flows in fluid film bearings, the approaches are dynamically equivalent and
Many of the older published reports describing bearing identification experiments have not presented confidence
intervals for the measured coefficients, but more recent experimenters have included them in their published work[2,
3]. The equations of motion for fixed pad bearings are relatively well known and not repeated here[4]. Often the full
non-synchronous equations for tilting pad bearings, as given above, are not used in rotor dynamic analyses, although
recent work shows the necessity of considering the full equations instability analyses[5].
Hummel[6]. They represented the fluid film as a simple spring support, but their model was incapable of accounting
for the observed finite amplitude of oscillation of a shaft operating at a critical speed.
Concurrently, Newkirk[7]and New kirkand Taylor[8] described the phenomenon of bearing induced instability, which he
called oil whip, and it soon occurred to several investigators that the problem of rotor stability could be related to the
Ramsden[9] was the first to review the papers on the experimentally obtained journal bearing dynamic characteristics.
He concluded that a designer would require known stiffness and damping coefficients of the bearings. Since most of the
data available at that time were experimental only, he stressed the need for accurate scaling laws to be evolved to avoid
full-scale tests.
rotor dynamics. Several conclusions and recommendations were made by them, most importantly: (a) experimental
work in the field of rotor dynamics to study the influence of bearings and supports upon the rotor response was
required; (b) additional theoretical studies to consider the influence of thermal and elastic distortion, grooving
When TiO2, BaSO4, SiC and graphite were added simultaneously, the friction coefficient and wear rate of the
composites were decreased. With the increase of applied load, adhesive wear took a dominant place, which was
generally less dangerous for polymer composite sliding surface. The transfer films on the counterpart surface may be
of higher quality at higher load compared to that formed at lower load. With the formation of higher quality transfer
films, the plowing and scuffing will be abated, and the tribological behaviour was improved [11-12]. Besides, the
forming rate of transfer films may be enhanced at higher load, which can shorten the running-in period and is favorable
for improving the tribological properties of polymer composites. With further increase of applied load, the newly
formed wear debris would come into being a more integrated but thinner layer on the worn surface, which played an
2. Experimental Set-up
The test rig was developed has three subsystems namely mechanical system, an electrical control system and a
measurement system. The mechanical system has the ability to simulate typical bearing operating conditions and the
electrical control system allows the mechanical subsystem to be controlled for different tests.
A mechanical system was designed to operate the journal bearing. The experimental system consists of a three phase
AC driving motor, couplings, load set up, a ball bearing, a journal bearing with the main drive as the shaft. The load set
up is placed at one end of the test rig. The electric drive motor is connected to the main shaft which is coupled with a
hard rubber.
The journal bearing is tested and it is mounted at the right end of the drive train. In order to maintain the axial
displacement of the journal bearing, a pair of washers is installed on the fasteners. The washer acts as a stopper to
prevent axial movement and it also serves as a thrust bearing. The preliminary experimental results showed that the
high radial loading of the journal bearings generate a high temperature. In order to reduce the temperature, a rolling
bearing is placed between the motor and the journal bearing. Table 1 shows the dimensions of the journal bearing made
of composites.
This section discusses selection of materials, material composition, characteristics of composite material and
fabrication.
Selection of Materials
It is well known that the main reason for the failure of rotating parts of machines arise due to the wearing of the
moving parts that caused by rubbing of surfaces. It is therefore necessary that moving parts be designed in such a way
that the friction and wear are less. This can be ascertained by choosing newer materials which are wear resistant and
It is now well established that non-metallic materials are suitable options for the manufacture of bearings. They are
1. The lubricant is inadequate combined with high loads and at low speeds,
A key parameter for material selection is their wear performance in conditions where there is no lubrication of polymer
composites used in mechanical components[9] such type of components can be used in various types of wear
situations. The selection of material is based on their longevity and lower friction losses.
Material Composition
In this investigation, hybrid composite journal bearings made of glass/epoxy laminated composites were prepared and
tested under various conditions and compared with journal bearing made of gun metal. The material composition for
Biaxial
Designation Epoxy Filler Materials
S. No. E-Glass Fibre
of Material (wt%) (wt %)
(wt % )
1 GE 35 65 Nil
The following procedure was adopted to prepare the journal bearing specimens:
The E-glass /Epoxy based composites mixed with varying concentrations were prepared. Fabrication of the composites
is done at room temperature using hand layup techniques. The required ingredients of resin, hardener, and fillers were
mixed thoroughly in a basin. The glass fibre was positioned manually and the mixture was poured into the mould
cavity. The entrapped air was removed manually with squeezes or rollers to complete the bearing specimen and the
Step 1 : Apply the oil upper and lower surface of the tool (releasing agent).
Step 3 : Mix the Resin LY556: Hardener HY 951: Aluminium oxide and Silicon carbide
Step 4 : Wet the first layer and layup in to female tool and follow the same till the 8th layer is applied.
Step 5 : Fix the male tool with the female and clamp it tightly.
Step 7 : Post cure the model with the tool at 100 degree Celsius in a hot air oven.
Step 8 : Remove the model from the tool and trim the edges and clear as per the original model or drawing.
1) Calculation of diameter of the bearing from the power, torque and stress relationship T = 60P/2N
60 to 90 C
6) Select the value of bearing characteristic number, and from that, the parameter Z is determined.
9) The proper composite bearing material and other required dimensions for the journal are decided.
Starting of the work was done by assuming various parameters and using the predefined knowledge.
After designing the complete and allbasic dimensions are obtained, the solid works model will be designed.
For the design of the bearing several calculations have been done in order to come up with the correct set of solutions.
During the analysis of the model there can be several changes regarding the design.
Verification of design
After including the new set of designs it will be verified again in order to make it a successful analysis.
Conclusion
1) Out of the two materials considered, the most optimum material wasfound to be GEA2S2. The basis for this
2) The values of both materials are comparably close. The minute difference that GEA2S2 has over GEhas made us
3) On conducting the CFD analysis we can see the variables of the shaft.
These factors show the distribution of heat, velocity and pressure over the entire composite journal bearing.
References
1. He, M., Thermoelastohdrodynamic Analysis of Fluid Film Journal bearing, Ph.D. thesis, University of Virginia,
(2003).
3. Kostrzewsky,G.J.,andFlack,R.D.,
AccuracyevaluationofexperimentallyDeriveddynamiccoefficientsoffluidfilmbearings,PartI.
4 Allaire,P.E.,andFlack,R.D.,JournalBearingDesignforHigh-SpeedTurbomachinery,Proceedings of International
Conference on Bearing Design, Historical Aspects, Present Technology, and Future Problems, ASME,(1980).
(2007).
6. Hummel,C.,KristischeDrehzahlenalsFolgederNachgiebigkeitdesSchmiermittelsimLager,VDI-Forschungsheft,
8. Newkirk, B.L.,and Taylor, H.D., Shaft Whipping due to Oil Action in Journal Bearing, General Electric Review ,
pp.559568 (1925).
9. Ramsden,P., Review of Published Data and Their Application to the Design of Large Bearings for Steam
Turbines, Proceedings of Conference in Lubrication and Wear: Fundamentals and Application to Design, I
MechE,(1968).
10. Downson, D. and Taylor,C.M., The State of Knowledge in the Field of Bearing- Influenced Rotor Dynamics,
11. T. NarendiranathBabu, T. Manvel Raj, D. Rama Prabha Sliding wear characteristics of Basalt Fiberwith
GE/Epoxy/Al2O3/Sic hybrid Composites for Journal bearing material using Fish Oil Lubricant, International
12. T. NarendiranathBabu, D. Ramaprabha Sliding wear characteristics of Biaxial Glass Fiber withEpoxy/Al2O3/Sic
hybrid Composites for journal bearing liner using Sea Water Lubricant,International Journal of ChemTech
Corresponding Author:
T. Narendiranath Babu*,
Email: narendiranathbabu.t@vit.ac.in