Design Development of Bearing Failure Project Set Up

GRD Journals- Global Research and Development Journal for Engineering | Volume 3 | Issue 6 | May 2018

Design Development of Bearing Failure Project Set Up Prof. N. D. Patil Assistant Professor Department of Mechanical Engineering PVPIT Budhgaon

Prof. P. P. Awate Assistant Professor Department of Mechanical Engineering PVPIT Budhgaon

Abstract Rolling bearings are well precision, few cost but large amount used in all kinds of rotary machine. It takes long time for the human being to develop the bearing from the initial idea to the modern rolling bearing. The reason why bearing is used is that first it can transfer moment or force. Secondly and maybe more important is that it can be interchanged easily and conveniently when it’s broken. In today’s world maintenance of any machinery is very important in view of downtime of machinery. The bearing sector is one of the examples without which no single rotating machinery work. Production of bearing industries are of high value which leads to the aspects of bearing life & application in more demanding situations.

Keywords- Bearing Failues, Vibrations, Stresses Etc

I. INTRODUCTION A. Problem Statement and Background

Fig. 1: Failure of bearing waviness of bearing

Fig. 2: Ball Failure

The above diagrams are showing the failure modes of rolling contact bearings due to following reason:1) Inappropriate use of bearings. Improper selection.

2) Faulty installation or improper processing.

3) Improper lubricant, lubrication method or sealing device.

4) Inappropriate speed and operating temperature.

5) Contamination by foreign matter during installation.

6) Failure due to crack formation on ball bearing races.

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Design Development of Bearing Failure Project Set Up (GRDJE/ Volume 3 / Issue 6 / 012)

7) Abnormally heavy load.

II. PROJECT SCOPE In this project work we will analyze on ball bearing races and its effect on the functioning of bearings. In this we are going to analyse the three cases as below:1) Development of artificial crack on inner race.

2) Development of artificial crack on outer race.

3) Development of artificial deformation on ball.

A. Design and Development of Project Set Up for Analysis of Deep Groove Ball Bearing 1) 2) 3) – – – 4) 5) 6) 7)

1) Specification of proposed project set up Type: Single row deep groove ball bearing.

Power: - 1 hp.

Changing parameter:Development of artificial crack on inner race.

Development of artificial crack on outer race.

Development of artificial deformation on ball.

Overall dimensions (Tentative): 1200x 1200x 1500 mm Loading Capacity: up 200 kg.

Speed capacity:- Variable or adjustable as per requirement. (100 – 1500rpm) General Information: The machine consists of a measuring instruments such as temperature, Load digitally. Also the varying loading arrangement is given on hydrodynamic bearing.

2) Analysis of different critical parts of mechanism.

3) Analysis of bearing vibration with help of FFT analyzer.

4) Selection of materials and drives.

Fig. 3: Project set up

III. DESIGN OF EXPERIMENT SET UP A. Design of Drive Shaft Selection of motor

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Design Development of Bearing Failure Project Set Up (GRDJE/ Volume 3 / Issue 6 / 012)

The load required to apply on belt through flat belt and nut and bolt arrangement = 100 kg = 1000N Design load considered = 1.2 x 1000kg = 1200N

The applied load = P = 1200N The Tangential force F = µP = 0.3 x 1200 = 360N So Maximum Torque T = Effort x Radius of wheel = F x R Diameter of bearing housing = 80mm R = 40mm Total torque on crank = 360 x 40 = 14400N-m Maximum speed of testing 500 rpm

P = 754 watt By considering application and extra jerk and safe design prime mover power considered = 1 hp

IV. DESIGN OF SHAFT Considering, factor of safety = 4 As per Design data book shaft material is selected Carbon steel C40 C40= Sut=580N/mm2 , Syt=330N/mm2 σ = 145 N/mm2 As per ASME code 0.3 X Yield strength N/mm2 0.18 X ultimate strength N/mm2} whichever is smaller 0.3 x 330 = 99 N/mm2 0.18 x 580 = 104 N/mm2 From equation (a) & (b) Allowable stress value will be 99 N/mm2 If key ways will provide to shaft then τ = 99 x 0.75 = 74.25 N/mm2 Max torsional moment equation is given by

Where T = 14400N-mm By using above equation drive shaft dia d = 9.04mm

(a) (b)

A

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Design Development of Bearing Failure Project Set Up (GRDJE/ Volume 3 / Issue 6 / 012)

A. Design against Bending

Fig. 5: Drive shaft loading condition

P = 1200 N RA = 600N As per load condition and farm condition the total load on wheel is considered Calculation of bending moment at loading point P, Length of span = L = 400mm BM at M = 600x 200 = 120000N-mm

ĎŹ = 145 N/ mm2 considering factor of safety = 4 By using above equation drive shaft dia d = 20.35mm B From equation A and B we have selected the diameter of shaft = 20mm considering extra jerk and for safe design.

V. CONSTRUCTIONAL DETAILS

The proposed experiment set up is shown in the above schematic drawing. In which the developed bearing housing is mounted on a shaft and the shaft is supported with help of pillow block bearing as shown in fig. The bearing housing is proposed in such a way that in which we can able to change the different ball bearing races. In this set up the loading arrangement also developed as shown in fig. For loading on bearing housing we have used the spring and belt arrangement. To measure load we will use the digital load cell. The motor is used for rotate the shaft as per requirement. The temperature we will measure by using thermocouple. we have arranged the temperature points in the housing as shown in fig and the temperature we will measure for different types of ball bearing races.

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Design Development of Bearing Failure Project Set Up (GRDJE/ Volume 3 / Issue 6 / 012)

VI. TESTING OF MACHINE To test and confirm the working of developed mechanism for analysis of ball bearing, we have taken practical demonstration at workshop. Also we have collected the feedbacks and improvements points in developed model.

Testing points and concluded points as below:Bearing shaft inner dia = 25mm

VII.

CONCLUSION

At constant speed and load for outer ring defected bearings, amplitude of vibration increases with increase in defect size. Similarly at constant speed and load for inner ring defected bearings, amplitude of vibration increases with increase in defect size. Hence it is concluded that, the outer ring defected bearings has higher amplitudes of vibration in comparison with inner ring defected bearings the same speed.

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M. Vijaya Kini, R. S. Pai, D. Srikanth Rao, Satish Shenoy B and R. Pai, “Effect of Groove Location on the Dynamic Characteristics of Multiple Axial Groove Water Lubricated Journal Bearing”, World Academy of Science, Engineering and Technology International Journal of Mechanical and Mechatronics Engineering Vol:3, No:12, 2009.

Dinesh Dhande , Dr D W Pande , Vikas Chatarkar, “ Analysis of Ball Journal Bearing Using Fluid Structure Interaction Approach” , International Journal of Engineering Trends and Technology, Vol-4, issue-8, May 2013.

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