Black oxide-coated bearings can help reduce operating and maintenance costs for wind turbines. Black oxide coating provides benefits like improved corrosion resistance, better performance in low lubrication, and reduced damage from cracking, smearing, and surface distress. Testing by SKF found failure rates of black oxide-coated bearings were 0.1% compared to 40-70% for standard bearings. By extending bearing life, black oxide coating can lower repair and downtime costs for wind turbines.
This document discusses Flygt's methods for analyzing and dimensioning the rotating systems of pumps and mixers. It focuses on shaft and bearing calculations. Bearings are key components that determine service intervals, so understanding failure factors is important. A correctly dimensioned shaft is also fundamental for smooth operation without issues like fatigue failures or natural frequency disturbances. Complex calculations are needed to model loads, geometries, stresses and lifetimes to create a robust design that can withstand unpredictable conditions. The document outlines Flygt's approaches to failure analysis, modeling, load calculations, stress analysis, and bearing lifetime predictions to enable long-lasting product performance.
A mechanical seal is a sealing device which forms a running seal between rotating and stationary parts. They were developed to overcome the disadvantages of compression packing. Leakage can be reduced to a level meeting environmental standards of government regulating agencies and maintenance costs can be lower.
This document is a training report submitted by Nishant Singh after completing a one-month training at Mecon Limited in Ranchi, India. The report focuses on the cold rolling mills section of the company. It provides details on the different types of cold rolling mills, the cold rolling process, annealing and skin passing processes. It also includes a basic overview of hydraulics and hydraulic components used in rolling mills like directional control valves, pumps and accumulators. The conclusion expresses gratitude to the officials at Mecon Limited for their support and for helping the author gain fundamental knowledge on cold rolling and mill operations.
SAP Parts Metal Face Seals are designed to offer the highest dependable leakage free Sealing performance in the tough farming environments , for the Axle & the transmission system of agriculture tractors and implements, comes with the engineered and proprietary processes, materials & elastomers.Get contact details - https://www.sapparts.com/mechanical-face-seal.html
Specialized bolt lubricants for oil & gas markets from Project Sales CorpProject Sales Corp
Project Sales Corp brings lubricants from Molykote, Never-Seez, TS-Moly and Sweeney for the oil and gas industry in India. Molykote P 37 is designed for high-temperature bolts and nuts containing alloys of chromium, nickel and molybdenum to prevent corrosion and stress cracking. Never-Seez is an anti-seize compound that forms a protective film to prevent seizure even under heat, pressure and water exposure. Sweeney and TS-Moly products contain molybdenum disulfide for lubricating threaded connections and other joints in wet and corrosive environments like offshore oil platforms.
Balanced mechanical seals help maintain seal face closure under high pressure by locating the seal faces such that stuffing box pressure has less effect on closure. Mechanical seal failures typically occur when the seal's motion is restricted, heat causes O-rings to deteriorate, incompatible materials are used, or incorrect installation. Balanced seals and proper material selection can help minimize failures from heat and materials issues, while correct installation prevents problems from restricted motion.
Mechanical seals provide a running seal between rotating and stationary parts in pumps. They have advantages over conventional packing such as reduced leakage to meet environmental standards, lower maintenance costs, and ability to seal higher pressures. The basic components of a mechanical seal are the primary seal faces (one stationary, one rotating), secondary seals, and hardware. Seals work by creating a tight sealing contact between flat faces, and can be classified by type (pusher, unbalanced, etc.) and arrangement (single, double, cartridge). Proper seal selection requires considering the liquid, pressure, temperature, liquid characteristics, and reliability/emission needs.
This document discusses various modes of failure for components in industrial power transmission gear drives, including gears, shafts, bearings, and seals. It describes different types of gear failures such as surface fatigue (pitting), wear, plastic flow, and breakage. Pitting is subdivided into initial, destructive, and normal pitting. The document explains the causes and appearances of each failure mode with diagrams and photos. It aims to help identify the causes of problems in gear drives and indicate potential remedies.
This document discusses Flygt's methods for analyzing and dimensioning the rotating systems of pumps and mixers. It focuses on shaft and bearing calculations. Bearings are key components that determine service intervals, so understanding failure factors is important. A correctly dimensioned shaft is also fundamental for smooth operation without issues like fatigue failures or natural frequency disturbances. Complex calculations are needed to model loads, geometries, stresses and lifetimes to create a robust design that can withstand unpredictable conditions. The document outlines Flygt's approaches to failure analysis, modeling, load calculations, stress analysis, and bearing lifetime predictions to enable long-lasting product performance.
A mechanical seal is a sealing device which forms a running seal between rotating and stationary parts. They were developed to overcome the disadvantages of compression packing. Leakage can be reduced to a level meeting environmental standards of government regulating agencies and maintenance costs can be lower.
This document is a training report submitted by Nishant Singh after completing a one-month training at Mecon Limited in Ranchi, India. The report focuses on the cold rolling mills section of the company. It provides details on the different types of cold rolling mills, the cold rolling process, annealing and skin passing processes. It also includes a basic overview of hydraulics and hydraulic components used in rolling mills like directional control valves, pumps and accumulators. The conclusion expresses gratitude to the officials at Mecon Limited for their support and for helping the author gain fundamental knowledge on cold rolling and mill operations.
SAP Parts Metal Face Seals are designed to offer the highest dependable leakage free Sealing performance in the tough farming environments , for the Axle & the transmission system of agriculture tractors and implements, comes with the engineered and proprietary processes, materials & elastomers.Get contact details - https://www.sapparts.com/mechanical-face-seal.html
Specialized bolt lubricants for oil & gas markets from Project Sales CorpProject Sales Corp
Project Sales Corp brings lubricants from Molykote, Never-Seez, TS-Moly and Sweeney for the oil and gas industry in India. Molykote P 37 is designed for high-temperature bolts and nuts containing alloys of chromium, nickel and molybdenum to prevent corrosion and stress cracking. Never-Seez is an anti-seize compound that forms a protective film to prevent seizure even under heat, pressure and water exposure. Sweeney and TS-Moly products contain molybdenum disulfide for lubricating threaded connections and other joints in wet and corrosive environments like offshore oil platforms.
Balanced mechanical seals help maintain seal face closure under high pressure by locating the seal faces such that stuffing box pressure has less effect on closure. Mechanical seal failures typically occur when the seal's motion is restricted, heat causes O-rings to deteriorate, incompatible materials are used, or incorrect installation. Balanced seals and proper material selection can help minimize failures from heat and materials issues, while correct installation prevents problems from restricted motion.
Mechanical seals provide a running seal between rotating and stationary parts in pumps. They have advantages over conventional packing such as reduced leakage to meet environmental standards, lower maintenance costs, and ability to seal higher pressures. The basic components of a mechanical seal are the primary seal faces (one stationary, one rotating), secondary seals, and hardware. Seals work by creating a tight sealing contact between flat faces, and can be classified by type (pusher, unbalanced, etc.) and arrangement (single, double, cartridge). Proper seal selection requires considering the liquid, pressure, temperature, liquid characteristics, and reliability/emission needs.
This document discusses various modes of failure for components in industrial power transmission gear drives, including gears, shafts, bearings, and seals. It describes different types of gear failures such as surface fatigue (pitting), wear, plastic flow, and breakage. Pitting is subdivided into initial, destructive, and normal pitting. The document explains the causes and appearances of each failure mode with diagrams and photos. It aims to help identify the causes of problems in gear drives and indicate potential remedies.
This document discusses materials, heat treatments, and dimensional stability of rolling bearings used in SKF bearings. The key points are:
1) Bearing rings and rolling elements are made of through-hardening carbon chromium steel or case-hardening chromium-nickel steel and manganese-chromium steel.
2) Heat treatments include bainitic hardening, case hardening, and martensite hardening, each with advantages like dimensional stability or hardness, and disadvantages like cost or risk of cracks.
3) Dimensional stability is highest in bainite-hardened materials and martensite-hardened bearings can experience the most diameter change with heat.
An investigation and rectification on failure of bearings of casting shakeout...eSAT Journals
Abstract This project deals with investigation and rectification on failure of bearing of casting shakeout, required in foundry industries to separate solidified casting and sand from mould box. The failure of bearings is mainly due to brinelling tends to create cavities on the bearing raceway. This result in roller and inner races surface of spherical bearing get damage. The rectification of existing system uses four bearings as modified setup of existing system to distribute the load acting on shakeout aims at reducing this frequent breakdown, increases life of bearings and increases the productivity of plant. The software Pro-E wildfire 4 is used for modeling. Keywords: Brinelling, Casting shakeout, Spherical Roller bearing, and Bearing life
This document discusses different types of mechanical seals used in pumps:
Pusher seals have secondary seals that move along the shaft to maintain contact but are prone to hang-ups. Unbalanced seals are inexpensive but have a lower pressure limit. Conventional seals require setting and alignment but installation is relatively simple. Non-pusher seals do not move along the shaft, can handle various temperatures, and do not require a secondary seal. Balanced seals have higher pressure limits and generate less heat, making them suitable for liquids with poor lubricity. Cartridge seals have the seal premounted and directly fit over the shaft, lowering maintenance costs and reducing errors.
What is the difference between Mechanical Seal and Gland Packing? | LEAK-PACKLEAK-PACK
Here you know the difference between mechanical seal and gland packing. Both gland packing and mechanical seals are effective and useful. It depends on economic viability, personal preference and requirement specification for which one will be preferred.
- Most mechanical seals fail prematurely due to component damage from corrosion, physical damage from heat or pressure, or the seal faces opening due to issues like the shaft material, solids in the fluid, or changes in the fluid state.
- Proper seal design, using the right materials for the application, avoiding issues like a hardened shaft, and ensuring free movement of components can help prevent premature failure.
- Keeping the seal faces cool and lubricated is important for long life, and two hard faces should only be used when carbon faces cannot work for the application.
Seals are used to prevent fluid leakage. Mechanical seals specifically use two flat faces in contact that rotate to create a tight seal against leakage. They have primary sealing faces and secondary seals. Selection depends on factors like liquid properties, pressure, and temperature. Proper installation, material selection, and maintenance are important to prevent failures.
This document discusses mechanical seals which are used to prevent leakage in pumps and other equipment. It describes the need for seals to minimize leakage and prevent toxic fluids from escaping. Both static seals, used between non-moving parts, and dynamic seals, used between moving parts, are covered. Common static seals include gaskets and O-rings, while dynamic seals include gland packings and mechanical contact seals. The document focuses on mechanical seals, explaining their design features such as seal faces, springs, and secondary seals. Different types are classified including single versus multiple spring seals, pusher versus non-pusher seals, and single versus double/tandem arrangements. Materials of construction and operating principles are also summarized.
A disc brake is a type of brake that uses the calipers to squeeze pairs of pads against a disc or rotor to create friction. This action slows the rotation of a shaft, such as a vehicle axle, either to reduce its rotational speed or to hold it stationary. The energy of motion is converted into waste heat which must be dispersed. Disc brake system is widely used on front wheels in mid range two wheeler such as - commuter and sports bikes. The Disc brake system is used on the front wheels of most hatchback cars, entry level sedans and MUVs whereas, it is also widely used on both front and rear wheels of high end cars and SUVs in combination with hydraulic vacuum brake actuating systems. Vikrant Yadav | Pankaj Yadav "Overview of Disc Brake" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-4 | Issue-4 , June 2020, URL: https://www.ijtsrd.com/papers/ijtsrd31530.pdf Paper Url :https://www.ijtsrd.com/engineering/automotive-engineering/31530/overview-of-disc-brake/vikrant-yadav
Mechanical seals are key components in centrifugal pumps that prevent fluid from leaking out of the pump casing. They consist of two faces, one stationary and one rotating, located between the impeller and rear casing. Pumps in harsh environments require more abrasion-resistant seals than regular pumps. Mechanical seals reduce leakage compared to gland packings, saving power. Proper flushing plans are needed to lubricate, cool, and clean the seal while removing particles to minimize abrasion and extend seal life. Common operational and maintenance errors that reduce seal life include dry running, suction choking, foreign materials, improper flushing plans, misalignment, stuffing box issues, and failed bearings.
This document discusses techniques for main bearing preventative maintenance and condition monitoring. It recommends manual inspection of bearings every two years if using manual re-lubrication, and inspection before installing automatic lubrication systems. Condition monitoring faces challenges due to slow shaft speeds and variable operating conditions, but vibration analysis can detect bearing defects, especially when measuring acceleration spectra. Connecting condition monitoring systems to automatic lubrication can provide lubrication on demand when bearing issues are detected.
Hydraulic seals are non-metallic rings that block or separate fluid in reciprocating motion applications, providing a way for fluid power to be converted to linear motion. Seals can be positive or non-positive based on leakage, static or dynamic based on relative motion, and come in shapes like O-rings, quad rings, V-packing, and composite seals. The type of seal used depends on factors like pressure, temperature, operational speed, and compatibility with fluids. Common sealing materials include leather, rubbers, plastics, and metals.
Mechanical face Seals are designed to be employed in
most abusing working conditions, accepted worldwide
to use in extremely harsh environments under enormous
stresses, sand, dirt, mud, dust and earth material.
This document discusses different types of bearings and their failure modes. It describes rolling contact bearings and their parts. Common failures for rolling contact bearings include wear damage, smearing, false brinelling, and corrosion. Cage failures include wear from contamination, tilting, and fractures. Sliding contact bearings are also discussed. Journal bearing failures like seizure, wear, oil whirl, and oil whip instabilities are explained. The document concludes by discussing research on air foil bearings which don't require external lubrication systems and their potential advantages and challenges.
sealing system for rotating shafts ( mechanical seals and packing )elkeik
This document provides an overview of mechanical seals and packing seals used to seal rotating shafts. It discusses the basic components and functioning of packing seals, including stuffing boxes, packing rings, and gland packings. It then summarizes the components and lubrication of mechanical seals, including primary and secondary seals. Various types of mechanical seals are classified by arrangement, including single seals, dual seals, and configurations such as inside versus outside mounted seals.
mechanical seals are an integral part on all fluid pumps and are a viable alternative for lip seals as well as packed glands. In practical applications, using these seals has been proven to increase pump longevity and make them usable for extended periods of time. http://www.sealsales.com/
This document provides an overview of fundamentals of mechanical seals including:
- Historical development showing how mechanical seals replaced packing seals.
- Definitions and basic components of mechanical seals such as stationary and rotary faces.
- Classification of mechanical seals by arrangement (single, dual) and design (pusher, non-pusher).
- Factors to consider when applying mechanical seals such as pressure, temperature and fluid properties.
This document discusses ceramic disc brakes. It begins by introducing ceramic brakes, noting they have better stopping capability and heat resistance compared to other brake types. It then discusses the construction of ceramic brakes, including that ceramic brake pads are made from ceramic fibers, fillers, and bonding agents. The document provides an exploded view of a brake caliper assembly and discusses the features of ceramic discs, including that they are abrasion resistant and heat resistant. It notes the advantages of ceramic brakes are their lighter weight, high friction values, resistance to high temperatures, and longevity without maintenance. The main disadvantage is their high initial and production costs.
Bend twist coupling and its effect on cavitation inception of composite marin...IAEME Publication
This document summarizes a research study on using bend-twist coupling in composite materials to enhance the performance of marine propellers in terms of cavitation inception. The study uses numerical modeling to analyze the effects of different ply stacking sequences in a composite laminate on propeller performance characteristics like thrust, torque and cavitation inception angle. Experimental validation is also carried out in a cavitation tunnel. Results show that a composite propeller's ply sequence can be tailored to improve performance metrics like cavitation inception speed compared to a metallic propeller.
Analysis of Bearing and Shaft Failures in Motors.pdfZiad Salem
This document discusses bearing and shaft failures in electric motors. It provides details on bearing stresses, fundamentals, loading principles, lubrication, failure analysis methodology and common failure modes. The key points are:
- Bearing failures account for 50-65% of motor failures, with improper lubrication, contamination, excessive loads and vibration being common causes.
- Proper lubrication and avoiding contamination are critical for bearing life. Grease is most common for small/medium motors, with polyurea greases suitable for higher temperatures.
- A methodology is presented to accurately diagnose bearing failures which considers the failure mode, pattern, appearance, application and maintenance history. The most common failure modes result from fatigue, fret
This document discusses materials, heat treatments, and dimensional stability of rolling bearings used in SKF bearings. The key points are:
1) Bearing rings and rolling elements are made of through-hardening carbon chromium steel or case-hardening chromium-nickel steel and manganese-chromium steel.
2) Heat treatments include bainitic hardening, case hardening, and martensite hardening, each with advantages like dimensional stability or hardness, and disadvantages like cost or risk of cracks.
3) Dimensional stability is highest in bainite-hardened materials and martensite-hardened bearings can experience the most diameter change with heat.
An investigation and rectification on failure of bearings of casting shakeout...eSAT Journals
Abstract This project deals with investigation and rectification on failure of bearing of casting shakeout, required in foundry industries to separate solidified casting and sand from mould box. The failure of bearings is mainly due to brinelling tends to create cavities on the bearing raceway. This result in roller and inner races surface of spherical bearing get damage. The rectification of existing system uses four bearings as modified setup of existing system to distribute the load acting on shakeout aims at reducing this frequent breakdown, increases life of bearings and increases the productivity of plant. The software Pro-E wildfire 4 is used for modeling. Keywords: Brinelling, Casting shakeout, Spherical Roller bearing, and Bearing life
This document discusses different types of mechanical seals used in pumps:
Pusher seals have secondary seals that move along the shaft to maintain contact but are prone to hang-ups. Unbalanced seals are inexpensive but have a lower pressure limit. Conventional seals require setting and alignment but installation is relatively simple. Non-pusher seals do not move along the shaft, can handle various temperatures, and do not require a secondary seal. Balanced seals have higher pressure limits and generate less heat, making them suitable for liquids with poor lubricity. Cartridge seals have the seal premounted and directly fit over the shaft, lowering maintenance costs and reducing errors.
What is the difference between Mechanical Seal and Gland Packing? | LEAK-PACKLEAK-PACK
Here you know the difference between mechanical seal and gland packing. Both gland packing and mechanical seals are effective and useful. It depends on economic viability, personal preference and requirement specification for which one will be preferred.
- Most mechanical seals fail prematurely due to component damage from corrosion, physical damage from heat or pressure, or the seal faces opening due to issues like the shaft material, solids in the fluid, or changes in the fluid state.
- Proper seal design, using the right materials for the application, avoiding issues like a hardened shaft, and ensuring free movement of components can help prevent premature failure.
- Keeping the seal faces cool and lubricated is important for long life, and two hard faces should only be used when carbon faces cannot work for the application.
Seals are used to prevent fluid leakage. Mechanical seals specifically use two flat faces in contact that rotate to create a tight seal against leakage. They have primary sealing faces and secondary seals. Selection depends on factors like liquid properties, pressure, and temperature. Proper installation, material selection, and maintenance are important to prevent failures.
This document discusses mechanical seals which are used to prevent leakage in pumps and other equipment. It describes the need for seals to minimize leakage and prevent toxic fluids from escaping. Both static seals, used between non-moving parts, and dynamic seals, used between moving parts, are covered. Common static seals include gaskets and O-rings, while dynamic seals include gland packings and mechanical contact seals. The document focuses on mechanical seals, explaining their design features such as seal faces, springs, and secondary seals. Different types are classified including single versus multiple spring seals, pusher versus non-pusher seals, and single versus double/tandem arrangements. Materials of construction and operating principles are also summarized.
A disc brake is a type of brake that uses the calipers to squeeze pairs of pads against a disc or rotor to create friction. This action slows the rotation of a shaft, such as a vehicle axle, either to reduce its rotational speed or to hold it stationary. The energy of motion is converted into waste heat which must be dispersed. Disc brake system is widely used on front wheels in mid range two wheeler such as - commuter and sports bikes. The Disc brake system is used on the front wheels of most hatchback cars, entry level sedans and MUVs whereas, it is also widely used on both front and rear wheels of high end cars and SUVs in combination with hydraulic vacuum brake actuating systems. Vikrant Yadav | Pankaj Yadav "Overview of Disc Brake" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-4 | Issue-4 , June 2020, URL: https://www.ijtsrd.com/papers/ijtsrd31530.pdf Paper Url :https://www.ijtsrd.com/engineering/automotive-engineering/31530/overview-of-disc-brake/vikrant-yadav
Mechanical seals are key components in centrifugal pumps that prevent fluid from leaking out of the pump casing. They consist of two faces, one stationary and one rotating, located between the impeller and rear casing. Pumps in harsh environments require more abrasion-resistant seals than regular pumps. Mechanical seals reduce leakage compared to gland packings, saving power. Proper flushing plans are needed to lubricate, cool, and clean the seal while removing particles to minimize abrasion and extend seal life. Common operational and maintenance errors that reduce seal life include dry running, suction choking, foreign materials, improper flushing plans, misalignment, stuffing box issues, and failed bearings.
This document discusses techniques for main bearing preventative maintenance and condition monitoring. It recommends manual inspection of bearings every two years if using manual re-lubrication, and inspection before installing automatic lubrication systems. Condition monitoring faces challenges due to slow shaft speeds and variable operating conditions, but vibration analysis can detect bearing defects, especially when measuring acceleration spectra. Connecting condition monitoring systems to automatic lubrication can provide lubrication on demand when bearing issues are detected.
Hydraulic seals are non-metallic rings that block or separate fluid in reciprocating motion applications, providing a way for fluid power to be converted to linear motion. Seals can be positive or non-positive based on leakage, static or dynamic based on relative motion, and come in shapes like O-rings, quad rings, V-packing, and composite seals. The type of seal used depends on factors like pressure, temperature, operational speed, and compatibility with fluids. Common sealing materials include leather, rubbers, plastics, and metals.
Mechanical face Seals are designed to be employed in
most abusing working conditions, accepted worldwide
to use in extremely harsh environments under enormous
stresses, sand, dirt, mud, dust and earth material.
This document discusses different types of bearings and their failure modes. It describes rolling contact bearings and their parts. Common failures for rolling contact bearings include wear damage, smearing, false brinelling, and corrosion. Cage failures include wear from contamination, tilting, and fractures. Sliding contact bearings are also discussed. Journal bearing failures like seizure, wear, oil whirl, and oil whip instabilities are explained. The document concludes by discussing research on air foil bearings which don't require external lubrication systems and their potential advantages and challenges.
sealing system for rotating shafts ( mechanical seals and packing )elkeik
This document provides an overview of mechanical seals and packing seals used to seal rotating shafts. It discusses the basic components and functioning of packing seals, including stuffing boxes, packing rings, and gland packings. It then summarizes the components and lubrication of mechanical seals, including primary and secondary seals. Various types of mechanical seals are classified by arrangement, including single seals, dual seals, and configurations such as inside versus outside mounted seals.
mechanical seals are an integral part on all fluid pumps and are a viable alternative for lip seals as well as packed glands. In practical applications, using these seals has been proven to increase pump longevity and make them usable for extended periods of time. http://www.sealsales.com/
This document provides an overview of fundamentals of mechanical seals including:
- Historical development showing how mechanical seals replaced packing seals.
- Definitions and basic components of mechanical seals such as stationary and rotary faces.
- Classification of mechanical seals by arrangement (single, dual) and design (pusher, non-pusher).
- Factors to consider when applying mechanical seals such as pressure, temperature and fluid properties.
This document discusses ceramic disc brakes. It begins by introducing ceramic brakes, noting they have better stopping capability and heat resistance compared to other brake types. It then discusses the construction of ceramic brakes, including that ceramic brake pads are made from ceramic fibers, fillers, and bonding agents. The document provides an exploded view of a brake caliper assembly and discusses the features of ceramic discs, including that they are abrasion resistant and heat resistant. It notes the advantages of ceramic brakes are their lighter weight, high friction values, resistance to high temperatures, and longevity without maintenance. The main disadvantage is their high initial and production costs.
Bend twist coupling and its effect on cavitation inception of composite marin...IAEME Publication
This document summarizes a research study on using bend-twist coupling in composite materials to enhance the performance of marine propellers in terms of cavitation inception. The study uses numerical modeling to analyze the effects of different ply stacking sequences in a composite laminate on propeller performance characteristics like thrust, torque and cavitation inception angle. Experimental validation is also carried out in a cavitation tunnel. Results show that a composite propeller's ply sequence can be tailored to improve performance metrics like cavitation inception speed compared to a metallic propeller.
Analysis of Bearing and Shaft Failures in Motors.pdfZiad Salem
This document discusses bearing and shaft failures in electric motors. It provides details on bearing stresses, fundamentals, loading principles, lubrication, failure analysis methodology and common failure modes. The key points are:
- Bearing failures account for 50-65% of motor failures, with improper lubrication, contamination, excessive loads and vibration being common causes.
- Proper lubrication and avoiding contamination are critical for bearing life. Grease is most common for small/medium motors, with polyurea greases suitable for higher temperatures.
- A methodology is presented to accurately diagnose bearing failures which considers the failure mode, pattern, appearance, application and maintenance history. The most common failure modes result from fatigue, fret
This document discusses the applications of industrial tribology. It begins by defining tribology and the main causes of friction and wear between surfaces. It then discusses several industrial applications where tribology is important, including bearings, gears, cams, and automobile engines. For each application, the document discusses common failure mechanisms and how tribological principles can be applied to improve performance and reduce wear through methods like surface coatings, lubricants, and material selection. The document concludes by noting that understanding tribology can help conserve energy and that developing eco-friendly materials and lubricants can promote sustainability and reduce emissions.
This document provides an introduction to air bearings, including their advantages over rolling element bearings such as near-zero friction, wear, and ability to operate without lubrication. It describes the basic operating principles of aerostatic air bearings, which use a pressurized air supply to create an air film between surfaces. Key benefits discussed include zero friction, zero wear, higher speeds and stiffness, suitability for clean environments, and longevity. Commercial applications of air bearings mentioned include coordinate measuring machines, semiconductor manufacturing equipment, and high-precision machine tools.
SMART MANUFACTURING METHOD FOR PISTON ROD CHROME PLATINGIRJET Journal
This document compares the traditional hard chrome plating process for piston rods to a newer HVOF (High Velocity Oxy Fuel) process. Hard chrome plating is commonly used due to its durability and corrosion resistance, but contains toxic hexavalent chromium. HVOF offers superior performance and is more environmentally friendly. Testing showed HVOF coatings had higher hardness and better corrosion resistance than hard chrome coatings. HVOF also has fewer processing steps and does not release harmful emissions, making it a smarter manufacturing method for piston rod coating.
BEND-TWIST COUPLING AND ITS EFFECT ON CAVITATION INCEPTION OF COMPOSITE MARIN...IAEME Publication
Cavitation in marine propellers has adverse effects such as noise, erosion and vibrations which result in loss of lift and increase in drag. The radiated noise level of any form of cavitation is of the order of magnitude higher than the noise level of non-cavitating flow. This is used by navy ships to detect and locate other ships. Cavitation has to be discouraged from stealth point of view. Generally marine propellers are made with NAB. The NAB propeller can be replaced with the composite propeller which has intrinsic bend-twist coupling for performance enhancement.
This paper summarizes the development of an innovative bearing and seal package for roller cone drill bits used in demanding applications. Analysis found that mud intrusion into seals was a primary cause of bit failure. A new dual dynamic seal design was created with harder elastomers and a central energizer to compensate for vibration. Field testing of 28 bits with the new design showed a 26.9% improvement in seal life compared to previous designs. The new seal package improved bit reliability in challenging wells with formation transitions in southwest Oklahoma.
Design of Experiments and Optimization of Grouted Connections of Wind Turbine...IRJET Journal
This document summarizes a research paper that examines the design of experiments and optimization of grouted connections in steel monopile foundations for offshore wind turbines. The paper analyzes monopile foundations both with and without shear keys using finite element analysis in ANSYS. Key findings from the analysis include:
1) Boundary conditions were applied with a vertical load of 3528000N on the grout for monopiles both with and without shear keys.
2) A design of experiments approach was used to determine the effect of varying parameters on response variables. Sensitivity charts, histograms, and correlation matrices were used to analyze results.
3) Preliminary results showed preferable stresses for monopiles with shear keys compared to those without.
This document discusses various modes of failure for components in industrial power transmission gear drives, including gears, shafts, bearings, and seals. It describes different types of gear failures such as surface fatigue (pitting), wear, plastic flow, and breakage. Pitting is subdivided into initial, destructive, and normal pitting. The document explains the causes and appearances of each failure mode with diagrams and photos. Recommendations are provided for preventing or reducing failures based on their causes.
This document discusses the design and analysis of alloy wheels for cars. It begins by describing how three different wheel designs made of different materials (aluminum, magnesium, titanium) for a Volkswagen Polo were analyzed using Creo and ANSYS software. Static, dynamic, and fatigue analyses were performed to determine stresses, deformations, safety factors, and product life. It was found that aluminum has less deformation while magnesium is more durable. Therefore, a new alloy combining aluminum and magnesium was proposed. The production process for alloy wheels is also summarized, from melting and casting aluminum to heat treatments and finishing. Finally, prior studies on wheel loading analysis and comparing materials are reviewed before conclusions are drawn on the best design and material.
IRJET- Analysis of Static Load Bearing Capacity of the Ball Bearing – A ReviewIRJET Journal
The document summarizes research analyzing the static load bearing capacity of ball bearings. It discusses using finite element analysis to determine capacity without destructive testing. The research found a linear relationship between the deviation of capacity results from finite element vs practical testing and the bearing size. A linear interpolation equation was developed relating deviation to bearing size. Laboratory testing on bearings of different sizes validated the relationship and showed deformation increasing with load. The research concludes the equation can be used to determine static capacity from bearing size.
1. Prior to the 1970s, there was little understanding of how the manufacturing process impacted part performance. Failures were increasing costs.
2. The document discusses how traditionally manufactured surfaces can be unstable, while plateaued surfaces produced by mass finishing methods can improve load bearing and lubrication.
3. It provides examples of how plateau honing cylinder bores and gear conditioning processes have improved engine and gear performance and lifetimes by controlling peak and valley surface characteristics. Surface finish design is now recognized as important for part functionality and predictable performance.
Tribological Aspects of Internal Combustion EngineIRJET Journal
This document discusses tribological aspects of internal combustion engines. It begins by defining tribology as the study of interacting surfaces in relative motion, including friction, wear, and lubrication. It then discusses the various sources of friction losses in engines, including direct friction between components, pumping losses, blowby losses, and power used to drive accessories. Wear in engines can result from abrasion, adhesion, fatigue and other mechanisms. Effective lubrication is needed to minimize friction and wear between moving engine parts. The key functions of engine lubricants are discussed as well as different lubrication systems used in engines. The document concludes that minimizing friction through effective lubrication is important for optimizing engine performance and reducing wear on components.
Effect of Annealing on Erosion Behavior of Atmospheric Plasma Spray and High ...IRJET Journal
This document summarizes a study on the effect of annealing on the erosion behavior of tungsten carbide-chromium carbide-nickel coatings applied via atmospheric plasma spray (APS) and high-velocity oxy-fuel spray (HVOF). Samples were annealed at 550 degrees Celsius and tested for erosion resistance at 450-575 degrees using alumina powder. Results showed that both coatings exhibited improved hardness after annealing, with HVOF showing greater hardness gains and wear resistance than APS. HVOF coatings also demonstrated superior erosion performance compared to APS coatings and uncoated steel substrates across all test conditions due to retaining a higher percentage of hard carbides at elevated temperatures.
Surface condition impacts part performancweDave Davidson
1) Surface finish and the presence of burrs on aircraft and aircraft engine parts can significantly impact part performance and lifespan by increasing stresses, corrosion, and reducing sealing abilities.
2) Specialized finishing processes are used to remove burrs, round edges, and optimize surface texture in ways that reduce stresses, improve fatigue life, enhance corrosion resistance, and improve sealing of joints.
3) Paying close attention to edge and surface quality is important in aerospace applications due to the potential for catastrophic failure if surfaces are improperly finished or contain defects.
Surface condition impacts part performancweDave Davidson
1) Surface finish and the presence of burrs on aircraft and aircraft engine parts can significantly impact part performance and lifespan by increasing stresses, corrosion, and reducing sealing abilities.
2) Specialized finishing processes are used to remove burrs, round edges, and optimize surface texture in ways that reduce stresses, improve fatigue life, enhance corrosion resistance, and improve sealing of joints.
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Bearing are machine element that allow components
to move with respect to each other. A little consideration will
shows that some part of power wasted in overcoming the
frictional resistance and due to the contact of surfaces large
amount of wear and tear takes place between the contacted
surfaces. Hence to avoid wear and tear in sliding contact
bearing and to reduce frictional resistance the thin layer of fluid
is introduced which is called as lubricant. Air bearing are
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bearing like friction, wear, particulates, and lubricant handling
are avoided. There are advantages like precision positioning,
such as lacking backlash and static friction as well as in high
speed application. Other than this characteristics, stability is
also important factor in air bearing.
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How black oxide coated bearings can make an impact on cutting o&m costs for wind turbines
1. Technology (http://evolution.skf.com/category/technology/)
How black oxide-coated bearings can make an impact
on cutting O&M costs for wind turbines
Author: Kenred Stadler, SKF Program Manager Renewable Energy Application Development Centre, Schweinfurt,
Germany
Wind energy companies are constantly seeking ways to reduce turbine operating costs. Black oxide-coated
bearings are one solution. SKF offers an enhanced black oxidation process for bearings used in new and
existing installations.
Operation and maintenance (O&M) costs can constitute a significant proportion of running a wind turbine, up to 25 %
over the lifetime of a machine1; thus manufacturers and maintenance service providers are keen to adopt any
technology that makes a contribution to reduced maintenance and downtime. With this in mind, SKF is championing a
surface treatment based on an enhanced black oxidation process for bearings used in wind turbine applications.
Black oxide-treated bearings can replace conventional units as part of wind farm maintenance routines, as well as
being specified for new installations. This means that the benefits of black oxidation can be applied across the entire
wind energy industry.
SKF, as a global engineering company and a leading bearing supplier to the wind energy industry, has extensive
experience with wind turbine applications, from bearing design through to broad services covering condition monitoring,
lubrication systems, asset management and the provision of spare parts. Through SKF’s long involvement with the
wind energy industry, the company has identified a number of opportunities to improve operational reliability through
new products and processes such as the specially designed black oxidation treatment. This is a surface refinement
process that can deliver significant performance improvements at an acceptable cost.
Increasing demands on installations
Wind turbines are subject to widely varying temperatures, speeds and loads. This, combined with contamination,
moisture and chemical effects due to highly AW doped oils, means these conditions can sometimes considerably
shorten the bearing life cycle, if no preventive measures are taken. Also, as wind turbines have increased in size and
generating power, further demands are placed on key systems such as the gearbox.
The black oxidation process used by SKF offers enhanced protection against damage to bearing components,
particularly for the challenging operating conditions created by a shift from onshore to offshore installations and for
those constructions sited in increasingly harsh environments around the world.
While damage and failure rates of wind turbine gearboxes may vary according to the source of published data, a
benchmark has been reported by the EU-funded Reliawind study, which came out around 6 % per year. That study also
quoted publicly available data on the failure rate and downtime from large reliability surveys performed by
Landwirtschaftskammer in Schleswig-Holstein, Germany, and the Wissenschaftliches Mess- und
Evaluierungsprogramm of the Fraunhofer Institute in Kassel, Germany, and noted failure rates of around 10 %. While
these figures may be considered low when compared with other causes of breakdowns in the field, such as electrical
systems, the consequence of that failure can be heavy; damage and failures in mechanical drive trains can result in
high costs due to long downtimes.
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2. As an example, a bearing failing on a high-speed shaft of an onshore turbine can incur repair costs in the region of
several thousands of euros, assuming it is exchanged up-tower. However, if a planet bearing fails, then the whole
gearbox needs to be replaced, and the cost can easily exceed hundreds of thousands of euros when all costs are
factored in.
The main failure mechanisms
The types of damage that can be alleviated by the addition of a black oxide treatment to bearing components such as
the rings and rollers generally fall into categories such as cracks, sliding (smearing) and surface distress, as well as
environmental effects, such as moisture and chemical attack.
1. Cracks
Many premature wind gearbox bearing damages result in a failure mode that does not follow classical rolling contact
fatigue (RCF) mechanisms. These classical mechanisms are subsurface initiated fatigue as well as surface initiated
fatigue and can be predicted by standard bearing-life calculation methods, whereas premature white etching crack
(WEC) failures experienced in wind turbine bearings are not covered (fig. 1a). WEC refers to the appearance of the
altered steel microstructure when polishing and etching a microsection. Failures can be found at several bearing
locations, namely the planet bearings, intermediate shaft and high-speed shaft bearings.
The occurrence of premature failures due to WEC is widely discussed within the wind industry and is being
independently investigated by wind turbine manufacturers, gearbox manufacturers and bearing suppliers as well as
universities and independent institutes. Current hypotheses are focused on either hydrogen-enhanced WEC
developments or purely load/stress-related WEC developments, preferably at inclusions as well as at the surface, or
combinations of these.
2. Smearing (adhesive wear)
In lightly loaded roller bearings, pure sliding between rolling elements and inner ring can occur when there is a large
mismatch between the inner ring and roller set rotational speed. For demanding applications such as wind gearbox
high-speed shafts, idling conditions and changing of load zones can sometimes lead to high sliding risk.
In radially loaded roller bearings, the most critical zone where sliding can occur is the entrance of the rollers into the
load zone. While rotating, the rollers slow down in the unload zone of the bearing because of friction and subsequently
have to be suddenly accelerated as they re-enter the load zone. Resultant conditions can cause smearing (fig. 1b). The
microstructure of rollers and raceways is altered, and this results in local stresses that ultimately cause spalling and
bearing failure.
Full complement cylindrical roller bearings do not always have a separating lubricant film built up between the
contacting rollers due to opposing surface speed. Thin film or even mixed lubrication under high roller-to-roller contact
pressures leads to metallic contact between neighbouring rollers, and this then increases friction, which consequently
can lead to smearing and surface destruction.
3. Surface distress/microspalling
Many machine elements having rolling and sliding contacts (e.g., rolling bearings, gears and cam-followers) can
sometimes suffer from various types of damage. Amongst these are mild abrasive wear and microspalling. Surface
distress or microspalling occurs because of an insufficient oil film to separate the moving contacts; it is a form of
localized surface damage that occurs on both gear teeth and in bearings and is a common phenomenon found in wind
turbine gearboxes. Gear teeth are usually more affected than bearings. Nevertheless, if it happens to bearings, it can
be particularly detrimental to the bearing function. It alters the geometry of rollers and raceways, increasing internal
clearance and resulting in local stresses that ultimately cause spalling and bearing failure (fig. 1c). Contamination by
water in wind turbine gearboxes could also be a contributing factor.
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3. 4. Moisture corrosion
The water content of wind gearbox oils is often underestimated. The large temperature gradients in combination with
highly saturated water content (depending on oil type) can lead to the risk of “free water” and standstill corrosion (fig.
1d). Whereas the high risk to the application by free water is well known, the risk of different levels of dissolved water in
gearbox oil is still unclear. SKF investigations indicate a negative impact on bearing performance whenever a certain
amount of dissolved water is present.
5. Fretting corrosion
When the bearing shaft interface (inner ring bore – shaft seat) or the bearing housing interface (outer ring outside
surface – housing seat) are subjected to micro movements under varying loading conditions, the native oxide on the
steel surfaces can be removed. Furthermore, surface asperities can corrode and are torn off. These particles become
trapped in the contact, and if oxidizing agents such as moisture are also present, further corrosion happens at the
surface (fig. 1e) . Under load, the trapped air and moisture corrode the surface further and can lead sometimes to
further particle generation. These particles will act as grinding paste resulting in further loss in interference and
increased ring creep, or in the worst case (if corrosion particles remain trapped at the seat) to ring through cracking by
increased and too high local stress.
The black oxidation process used by SKF
For all these potential failure modes, applying a specially designed black oxide coating on the bearing functional
surfaces provides a significant degree of protection. This layer adds beneficial properties to the bearing operation, such
as an improved running-in phase, and results in equally improved surface properties after running-in, better
performance under poor lubrication regimes (low κ conditions) and better lubricant adhesion, as well as enhanced
smearing resistance. The risk of fretting, microspalling and crack formation can be reduced. Furthermore, the black
oxide layer offers an elementary corrosion resistance as well as an enhanced chemical resistance when compared with
untreated surfaces. The moderate corrosion resistance of black oxide is sufficient to suppress standstill corrosion and
fretting corrosion, and the chemical resistance reduces detrimental effects from aggressive oil ingredients. It improves
friction behaviour and reduces wear, particularly under mixed lubrication conditions. Recent R&D results indicate that
black oxide acts as a barrier to hydrogen permeation into the steel.
To give a comparison of the potential improvement in failure rates, a wind gearbox manufacturer has reported, in a
sample of 1,000 standard cylindrical roller bearings in a gearbox application, a failure rate ranging from 40 % to 70 %
(after two years). Subsequently, in a sample of 1,150 black oxidized cylindrical roller bearings for a similar application,
the failure rate was 0.1 % over the same period
2
.
In summary, compared with untreated bearings, black oxide-coated bearings from SKF in windmill turbine gearbox
applications (fig. 4) can offer the following benefits:
improved running-in behaviour
better corrosion resistance
improved resistance against smearing damage
better performance in low lubrication conditions
increased oil and grease adhesion
reduction of chemical attack from aggressive oil additives on the bearing steel
reduced hydrogen permeation in the bearing steel
decrease of fretting corrosion risk in the fits.
With more than 50,000 black oxide-coated bearings in the field, SKF has accumulated a wealth of evidence that this
cost-effective process can deliver appreciable performance improvements for the wind energy industry that can result
in fewer early failures and hence contribute to lower overall O&M costs.
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4. Black oxide treatment
Black oxide is a surface treatment that is formed by a chemical reaction at the surface layer of the bearing steel and is
produced when parts are immersed in an alkaline aqueous salt solution operating at a temperature of approximately
150 °C. The reaction between the iron of the ferrou s alloy and the reagents produces an oxide layer on the outer
surface of bearing components consisting of a well-defined blend of FeO, Fe
2
O
3
, resulting in Fe
3
O
4
. The result is a
dark black surface layer of approximately 1–2 µm in thickness.
The benefits of black oxide have to be judged for the individual application, but no detrimental effects of this treatment
are known at this time. It has been successfully applied to bearings in other industries with particular operational
challenges, such as paper machine rolls, machine tools and industrial fans.
The black oxidation process involves a wide variety of parameters. The total process consists of about 15 different
immersion steps; in many of these it is possible to vary chemical content, concentration, temperature, immersion time
and fluid behaviour within the tanks.
SKF has performed extensive research on this process since 2006 to define optimized treatment specifications for the
black oxide process, also extending it to the treatment of large bearings. The black oxidation processes from SKF are
designed and individually tailored for each bearing type and application to provide maximum performance and can deal
with a broad range of bearing sizes used in wind turbines currently up to 2.2 m outside diameter, with the weight of
individual bearing components up to 1,000 kg. The treatment method as well as the size and weight range is
proprietary to SKF.
SKF recommends that both inner and outer rings as well as the rolling elements are coated for the best performance.
The black oxide can be applied to all bearing types used in key wind turbine systems. Cylindrical and tapered roller
bearings in particular have been successfully treated and put into operation in recent years (figs. 2 and 3).
The black oxide treatment process used by SKF is carefully specified and precisely monitored, producing high-quality
bearings that can be accessed through the company’s global network, making the benefits of black oxide bearings
available to wind turbine manufacturers, end users and service providers worldwide.
Fig. 1: Types of bearing damage that can occur in wind gearboxes:
(http://evolution.skf.com/wp-content/uploads/2013/09/T_oxide01a_evo4132.jpg)
a) cracks/spalls.
(http://evolution.skf.com/wp-content/uploads/2013/09/T_oxide01b_evo4131.jpg)
b) sliding damage/smearing.
(http://evolution.skf.com/wp-content/uploads/2013/09/T_oxide01c_evo4131.jpg)
c) surface distress/microspalling.
(http://evolution.skf.com/wp-content/uploads/2013/09/T_oxide01d_evo4131.jpg)
d) moisture/standstill corrosion on a raceway.
(http://evolution.skf.com/wp-content/uploads/2013/09/T_oxide01e_evo4131.jpg)
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5. e) fretting corrosion in the bore of an inner ring.
(http://evolution.skf.com/wp-content/uploads/2013/09/T_oxide02_evo4131.jpg) (http://evolution.skf.com/wp-content/uploads
/2013/09/T_oxide03_evo4131.jpg) (http://evolution.skf.com/wp-content/uploads/2013/09/T_oxide04_evo4131.jpg)
Note
1. For a new turbine, O&M costs may easily make up 20–25 % of the total levelized cost per kWh produced over the
lifetime of the turbine. If the turbine is fairly new, the share may be only 10–15 %, but this may increase to at least
20–35 % by the end of the turbine’s lifetime. Figures from Wind Energy – The Facts (WindFacts), a European project
financed by the Intelligent Energy, Europe programme of the Executive Agency for Competitiveness and Innovation.
2. J.Luyckx, Hammering Wear Impact Fatigue Hypothesis WEC/irWEA failure mode on roller bearings, NREL
workshop, Broomfield, Colorado, USA, November 2011.
Author: Kenred Stadler, SKF Program Manager Renewable Energy Application Development Centre, Schweinfurt,
Germany
Tags: Cylindrical roller bearings (http://evolution.skf.com/categories/cylindrical-roller-bearings/) | Design
(http://evolution.skf.com/categories/design/) | Electricity, gas and water supply (http://evolution.skf.com/categories
/electricity-gas-and-water-supply/) | Lubricants (http://evolution.skf.com/categories/lubricants/) | Machinery and
equipment (http://evolution.skf.com/categories/machinery-and-equipment/) | Reliability (http://evolution.skf.com
/categories/reliability/) | Research & Theory (http://evolution.skf.com/categories/research-theory/) | Taper roller
bearings (http://evolution.skf.com/categories/taper-roller-bearings/)
If you are interested in using the text and images contained within this online magazine for publication, please contact
the Editor-in-Chief on e-mail EVOLUTION@SKF.COM (mailto:evolution@skf.com) for approval. You are welcome to
quote from our articles free of charge, but please credit the source as 'Evolution - the business and technology
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