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What is a Bearing? Robust Design Concurrent Engineering Centers of Action Constraint Preload Load/Life Lubrication Error Motions
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2/6/2002
What is a Bearing?
Bearing is defined by Websters to be a support or supporting part
In machine design, a bearing is a component that allows for relative motion between two bodies Your skeleton is the central structure that supports your body and its modules, your Your joints are bearings that allow different body modules to mo ve with respect to each other Bearings allow machines to move
Bearings can have many forms, but only two types of motions
Linear motion or rotary motion
In all bearings, cleanliness and surface finish are most important There are many different types of bearings
Sliding Rolling Flexing Fluid Film (hydrodynamic) All are designed using the same philosophy of understanding the flow of forces in the machine, and the mechanical constraints used to mount them
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2/6/2002
Robust Design
The bearings are the machine elements that allow components to move with respect to each other with a minimum amount of friction and wear. When designed, manufactured, and used properly, bearings will work great! The biggest killers of bearings are:
Overloading originates ouchies! Overconstraint ordains overloading! Maligned moments make a morass! Dirt decries disaster! Lubrication loss lessens life!
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2/6/2002
Concurrent Engineering
Bearings: For the concepts you are envisioning, how will you support moving components by linear or rotary motion? Concurrent engineering requires us to consider:
Structure: How can you use symmetry and monolithic features to provide support and ease installation? Kinematics: Do the bearings have the required range of motion, without jamming? Actuators, Sensors & Controls: Will be bearings withstand the actuator loads and speeds? Manufacturing: How do you make sure you can make it? Always think ahead to how will you make what you design!
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2/6/2002
Centers of Action
A body behaves as if all its mass in concentrated at its center of mass A body supported by bearings, behaves as if all the bearings are concentrated at the center of stiffness
The point at which when a force is applied to a locked-in-place axis, no angular motion of the structure occurs It is also the point about which angular motion occurs when forces are applied elsewhere on the body Found using a center-of-mass type of calculation (K is substituted for M) To find the X location of the center of stiffness with respect to an arbitrary coordinate system:
= center _ of _ stiffness
X K
i =1 i
X
i =1
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2/6/2002
Centers of Action
Moments are what cause bending and binding in the system, so if they can be minimized, this is good! If the actuation force acts through the center of mass:
There is no inertial moment on the body There are no reaction forces on the bearings
The center of mass and the center of stiffness do not necessarily have to be located at the same point
However, for stacked multi axis structures: The centers of mass of the axes move Locate the point of actuation at the nominal center of mass
If the force is located between the center of friction and the center of stiffness:
There will be no moment acting on the system The center of friction and the center of stiffness do not necessarily have to be located at the same point
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2/6/2002
Constraint
EVERY element has six degrees of freedom You MUST let move what you need to move
E.g., large degrees of freedom, your overall Design Parameters
You MUST NOT restrain natural error motions that exist to allow for misalignment between elements!
E.g., a cars drive shaft has universal joints at the ends and a spline (linear sliding) connection As the car flexes, these elements accommodate relative motion between the axle and the transmission E.g., shafts that bend a lot have their bearings in spherical mounts, or they use spherical roller bearings
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2/6/2002
Y Y Z
2000 Alexander Slocum 10-8
X
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Y Y Z Z
2000 Alexander Slocum 10-10
2/6/2002
Constraint: Saint-Venant
St. Venant: Linear Bearings:
Linear motion: L/D>1, 1.6:1 very good. 3:1 super ideal
Wheel
!!Non Optimal!!
Shaft
!!Optimal!!
2000 Alexander Slocum 10-11 2/6/2002
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Sometimes the inner and outer races need to be constrained, and sometimes only the inner race
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1.618:1
1:1
1.000
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Constraint: Jamming
When will a drawer jam?
When (F 2+F4)>FA, the slide jams! To be safe and conservative, create designs where the L/D ratio is greater than 1, and ideally L/D =3 when there is sliding friction!
F=0= F F F
2 4 2 4
M = 0 = F a+ F a F b + F b F L F w
2 4 L A
F (L a + b) + F w) F = 2a F (L + a + b) + F w) F = 2a
L A 4 L A 2
F 4 b
F 4
Y F w A X F2 F
2 L
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2/6/2002
= arcsin
( H)
2
= H (1 cos ) 2H
2000 Alexander Slocum 10-17 2/6/2002
Constraint: Structures
A bearing is only as good as the structure that supports it
Utilize symmetry whenever possible Asymmetric structures often have internal gradients, which are an indicator of potential problems
Start at the tool tip or workplace with estimates of forces and acceleration requirements
Work backward through the structural system and determine forces and moments on members Minimize the structural loop and use closed sections whenever possible Large plate sections should be stiffened with ribs or other means to keep them from vibrating like drumheads Bearings stiffness should be on the order of the structure: Use superposition!
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2/6/2002
Preload
Preload allows for bi-directional loading
If not careful, it can lead to over-constraint
Preload maximizes stiffness Preload deflection is small, so preload can be easily lost by manufacturing error or wear
Preload loss via wear is avoided with the use of spring loaded preload systems
Spring loaded preload systems accommodate rail thickness variations without a large change in preload force
Spring loaded preload systems have limited force and moment capability Springs can be disk washers, or the deformation of the structure
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2/6/2002
Preload: Mechanics
Sum of the forces:
Fload - ( Fpreload + Kupper pad ) + ( F preload - Klower pad ) = 0
Careful of preload forces not being overcome by load, or stiffness falls to Klower pad
No preload
Preloaded
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2/6/2002
K x + end dx = K L + end L 2
L
F =
0
Using the above to substitute first for end and then , the slope of the carriage and the deflection end at the end are respectively:
= 12F( - L/2) L K
2
6 - L/2 end = F 1 K L
The moment applied to the carriage about its centroid is simply F( - L/2), so the rotational stiffness of the carriage about its centroid is:
2 Krotational @ centroid = KL 12
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2/6/2002
The translational stiffness of the system at the center of stiffness will be:
KY = 4KbY KZ = 4KbZ
The moment stiffness at the bearing center of stiffness will be:
Y
KX = KY =
KbYL2 Z KbZL2 X
x 4, 0, z 4
x 3, 0, z 3
FY x FY y FY z FY , , FX x FX y FX z FX , ,
x i,j, 0, z i,j
FZ xFZ, y FZ, z FZ
x 2, 0, z 2
KZ = KbYL2 X
2000 Alexander Slocum 10-23
Z (j direction) x 1, 0, z 1
X (i direction)
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2/6/2002
Load/life
Your machines will have to withstand at most 6 actual runs on the contest table, BUT dozens and dozens of trial runs You need to design and engineer the components for long life
Structural fatigue Bearing wear
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2/6/2002
http://www.dupont.com/enggpolymers/americas/products/deldata.html The maximum tensile stress we should be putting on the material is 10ksi The maximum contact pressure for a material is typically sqrt(3) times the yield strength (Von Mises criteria) Perform calculations and if in doubt, do a Bench Level Experiment
10-27
2/6/2002
dM = 2 xdF =
2x
3
dPdx
dP =
3M
Bearing_Pitch_PV By Alex Slocum 3/8/98 To determine bearing contact pressure in a slider loaded by a moment Dimensions in inches and pounds Enter numbers in bold Total slider length 1.5 Slider contact width 0.25 Pivot point height above center of stiffness 1 Force 150 Max PV (psi-ips) 4000 Moment 150 Maximum contact pressure 1600 Speed (inchs/sec) 1 PV (psi-inch/sec) 1600
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2/6/2002
Be very careful to make the bearings robust enough to handle side loads (prevent wobble)! Make sure the actuator is mounted using clevis so bending moments are not transmitted to the actuator! Sloppy pin joints are often sufficient to function as clevises Also check the PV value: Load*Velocity<Bearing Max value
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2/6/2002
Load/Life: L10
Rolling element bearings have an L10 life
The allowable load for a given number of revolutions where only 10% of the bearings will fail La: millions of revolutions.
a1: 1.0 for a 10% probability of failure a2: a materials factor, which is typically 3.0 for steel bearings . a3: lubrication factor, which typically is 1.0 for oil mist. C: basic dynamic load rating from a table of available bearings. Fe: the applied equivalent radial load, determined by bearing type. : 3 for balls and 10/3 for rollers. Precision life is about 90% of the L10 life
For high speed applications, the operating speed must be taken into account when calculating the equivalent radial load Fe K: rotation factor = 1 for rotating inner ring and 2 for a rotating outer ring Kr: radial load factor = 1 (almost always) KA: axial load factor
Fe = K Kr Fr + KA FA
L a = a1 a2 a3 (C/ F e)
10-30 2000 Alexander Slocum 2/6/2002
Molded nylon PRB 200,000 250,000 200,000 250,000 pressed-steel 250,000 300,000 250,000 300,000 Molded nylon PRB 200,000 200,000 pressed-steel 200,000 250,000 -
Molded nylon PRC composite CR (ring piloted) 300,000 350,000 300,000 400,000 Molded nylon PRB 200,000 250,000 pressed-steel 200,000 250,000 Metallic (ring-piloted) 250,000 300,000 -
(1) Grease filled to 30 to 50% of capacity. Type of grease must be carefully chosen to achieve the above speed values. Consult Fafnir for complete recommendations. (2) For oil bath lubrication, oil level should be maintained between 1/3 to 1/2 from the bottom of the lowest ball.
10-31
2/6/2002
Lubrication
Lubrication
Separates the structural materials, and prevents chemical bonding. Allows for viscous shear of a fluid thereby reducing material wear Tribology is the study of lubrication and wear Oil is the most common lubricant Grease is just a soap that holds oil and releases it as it gets hot LESS IS BETTER! Lubricants attract dirt, and thus cleanliness (via seals) it of extreme importance! E.g., porous bronze bushings E.g., Teflon, Rulon, Delrin.
Some bearings are impregnated with solid lubricants which are released as they get hot
Some bearings are inherently lubricious and can function dry In general, these bearings do even better when also lubcricated Measure coefficient of friction by an incline plane: =tan
Sliding contact (e.g., plastic on metal) with modest friction (=0.1-0.05) Rolling elements (e.g., ball bearings) with very low friction (=0.01-.005)
10-32
2/6/2002
Ra = 1 L
y(x)dx
0
Sliding contact bearings tend to average out surface finish errors and wear less when the skewness is negative
Negative skewness holds the lubricant As the system heats up, the lubricant flows and the friction drops The larger the positive skewness, the greater the wear-in period
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2/6/2002
Lubrication: Regions
There are three regions of lubrication as shown by the Stribeck curve Boundary, or sliding contact, where there is sliding contact between bodies, or the lubricant layer is very thin and the relative velocity is very low Coefficients of friction are on the order of 0.05-0.15 for bearing materials Surface speeds are less than 3 m/min Mixed, where there is partial separation of the sliding surfaces by hydrodynamic action of the lubricant film, but there is still some solid rubbing Coefficients of friction are on the order of 0.02-0.1 for bearing materials Full Film (hydrodynamic), where there is separation of the sliding surfaces by hydrodynamic action of the lubricant film Coefficients of friction are on the order of 0.001-0.005 Friction also depends on velocity and lubricant viscosity George Gabriel Stokes (1819-1903) Surface speeds are greater than 5 m/min Stiction: when static is greater than dynamic , cause stick-slip which causes position errors Static friction never equals dynamic friction.
Boundary Mixed Full film (Hydrodynamic) Friction
Osborne Reynolds (1842 - 1912) Claude Louis Marie Henri Navier (1785-1836)
10-34
Velocity
2/6/2002
Still, static friction approximately equals dynamic friction at low speeds, so stick slip is often minimized For heavily loaded tables, static friction is still significantly greater than dynamic friction Effect of stick-slip in a machine used to cut a hole using circular interpolation:
Errors will appear at velocity crossovers: 10-20 microns for sliding contact bearings 5 microns for rolling element bearings
10-35
2/6/2002
The rolling bearing pulls in lubricant, whose viscosity increases with pressure, to form an elastohydrodynamic lubrication layer between the ball and the race The EHD layer accommodates the differential slip, but generates heat via viscous shear
The geometry of the rolling contact interface also plays a significant role
10-36
2/6/2002
Error Motions
Bearings are not perfect, and when they move, errors in their motion can affect system performance
Accuracy standards are known as (ABEC) classes as set by the Annular Bearing Engineers Committee of the Anti-Friction Bearing Manufacturers Association, Inc. (AFBMA) ABEC 3 rotary motion ball bearings are common and low cost ABEC 9 rotary ball bearings are used in the highest precision machines
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2/6/2002
Precision Machine Designers measure error motions and use FFTs to determine what is causing the errors
MRS center error motion value PC center error motion value PC center
Inner motion
500
Displacement (nanometers)
400
300
200
100
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2/6/2002
Peaks likely due to rolling elements (ball and cam roller surface errors) Surface finish effects Overall bow in rail
1.00E-01
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