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Applied Tribology AppliedTribology:BearingDesignandLubrication, Second Edition. M.M.KhonsariandE. R.Booser ©2008JohnWiley&Sons,Ltd. ISBN: 978-0-470-05711-7 TribologySeries Editors:MJNeale,MPriestandGStachowiak KhonsariandBooser AppliedTribology–Bearing April2008 DesignandLubrication,2nd Edition Stachowiak(ed) Wear – Materials, November2005 MechanismsandPractice Lansdown LubricationandLubricant November2003 Selection,3rd Edition Neale,PolakandPriest(eds) Handbook of Surface May2003 TreatmentandCoatings Sherrington,RoweandWood TotalTribology–towardsan December2002 (eds) integratedapproach Kragelsky,Alisin,Myshkin Tribology–Lubrication, April2001 andPetrokovets(eds) FrictionandWear Stolarski&Tobe RollingContacts December2000 NealeandGee GuidetoWearProblemsand October2000 TestingforIndustry Comingsoon MartinandOhmae Nanolubricants April2008 Applied Tribology Bearing Design and Lubrication Second Edition Michael M. Khonsari Dow Chemical Endowed Chair in Rotating Machinery Department of Mechanical Engineering Louisiana State University, USA E. Richard Booser Engineering Consultant Copyright©2008 JohnWiley&SonsLtd,TheAtrium,SouthernGate,Chichester, WestSussexPO198SQ,England Telephone (cid:2)+44(cid:3)1243779777 Email(forordersandcustomerserviceenquiries):[email protected] VisitourHomePageonwww.wiley.com AllRightsReserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystemortransmittedin anyformorbyanymeans,electronic,mechanical,photocopying,recording,scanningorotherwise,exceptunder thetermsoftheCopyright,DesignsandPatentsAct1988orunderthetermsofalicenceissuedbytheCopyright LicensingAgencyLtd,90TottenhamCourtRoad,LondonW1T4LP,UK,withoutthepermissioninwritingof thePublisher.RequeststothePublishershouldbeaddressedtothePermissionsDepartment,JohnWiley&Sons Ltd,TheAtrium,SouthernGate,Chichester,WestSussexPO198SQ,England,oremailedto [email protected],orfaxedto(+44)1243770620. Designationsusedbycompaniestodistinguishtheirproductsareoftenclaimedastrademarks.Allbrandnames andproductnamesusedinthisbookaretradenames,servicemarks,trademarksorregisteredtrademarksoftheir respectiveowners.ThePublisherisnotassociatedwithanyproductorvendormentionedinthisbook. Thispublicationisdesignedtoprovideaccurateandauthoritativeinformationinregardtothesubjectmatter covered.ItissoldontheunderstandingthatthePublisherisnotengagedinrenderingprofessionalservices.If professionaladviceorotherexpertassistanceisrequired,theservicesofacompetentprofessionalshouldbe sought. OtherWileyEditorialOffices JohnWiley&SonsInc.,111RiverStreet,Hoboken,NJ07030,USA Jossey-Bass,989MarketStreet,SanFrancisco,CA94103-1741,USA Wiley-VCHVerlagGmbH,Boschstr.12,D-69469Weinheim,Germany JohnWiley&SonsAustraliaLtd,42McDougallStreet,Milton,Queensland4064,Australia JohnWiley&Sons(Asia)PteLtd,2ClementiLoop#02-01,JinXingDistripark,Singapore129809 JohnWily&SonsCanadaLtd,6045FreemontBlvd,Mississauga,ONT,L5R4J3 Wileyalsopublishesitsbooksinavarietyofelectronicformats.Somecontentthatappearsinprintmaynotbe availableinelectronicbooks. LibraryofCongressCataloginginPublicationData Khonsari,MichaelM. Appliedtribology:bearingdesignandlubrication/MichaelKhonsari,EarlRichardBooser.—2nded. p. cm. Includesbibliographicalreferencesandindex. ISBN978-0-470-05711-7(cloth) 1. Tribology. 2. Bearings(Machinery)—Designandconstruction. I. Booser,E.Richard. II. Title. TJ1075.K462008 621.8(cid:2)9—dc22 2008009590 BritishLibraryCataloguinginPublicationData AcataloguerecordforthisbookisavailablefromtheBritishLibrary ISBN978-0-470-05711-7 Typesetin10/12ptTimesbyIntegraSoftwareServicesPvt.Ltd,Pondicherry,India PrintedandboundinGreatBritainbyAntonyRoweLtd,Chippenham,Wiltshire Dedicated to: Karen, Maxwell, Milton and Mason Khonsari and Katherine Booser Contents SeriesPreface ix Preface xi Part I General Considerations 1 1 Tribology–Friction,Wear,andLubrication 3 2 LubricantsandLubrication 23 3 SurfaceTextureandInteractions 63 4 BearingMaterials 89 Part II Fluid-Film Bearings 113 5 FundamentalsofViscousFlow 115 6 ReynoldsEquationandApplications 143 7 ThrustBearings 173 8 JournalBearings 201 9 Squeeze-FilmBearings 263 10 HydrostaticBearings 299 11 GasBearings 321 12 DryandStarvedBearings 361 viii Contents Part III Rolling Element Bearings 389 13 SelectingBearingTypeandSize 391 14 PrinciplesandOperatingLimits 425 15 Friction,WearandLubrication 459 Part IV Seals and Monitoring 16 SealFundamentals 487 17 ConditionMonitoringandFailureAnalysis 531 AppendixA UnitConversionFactors 551 AppendixB ViscosityConversions 555 Index 557 Series Preface Thefirsteditionofthisbookwaspublishedin2001.Thebookhasquicklybecomeahighly successfulandpopulartextamongstthestudents,academicsaswellasamongstthepracticing engineers.Thereadersvaluedthisbookasagoodteachingmaterialandausefulreference.It isthusofnosurprisethatitenjoysafivestarrankingontheAmazonbooklist.Thesecond editionisanextendedandupdatedversionoftheoriginal.Theneweditionfollowsthesame format as the first edition and covers topics such as tribology in bearings followed by the demonstrationsoftheapplicationsofthesamebasicprinciplestoothermachinecomponents suchaspistonpins,pistonrings,seals,viscouspumps,viscousdampers,hydrauliclifts,wet clutchesandbrakes.Newadditionsincludetwonewchaptersondynamicsealsandbearing failure modes. The chapter on bearing failure modes is an especially welcomed addition as it completes the bearing’s ‘life cycle’ from design to its failure. The practical aspects of bearing’s failure are rather rarely discussed in the textbooks. Information provided in this chapter would be equally valuable for practicing engineers, designers, academics and the students.Thetextintheremainingchaptershasbeenupdatedandissupportedbynumerous numerical examples. A manual with solutions adds to the attractiveness of this book as a teaching material in the classroom. Therefore this book is highly recommended as both the textbook to be used in teaching undergraduate and postgraduate courses in tribology and machine design as well as the preferred reference book for practicing engineers and designers. Gwidon Stachowiak University of Western Australia Perth, Australia Preface Tribologyisadiversefieldofscienceinvolvinglubrication,friction,andwear.Inadditionto covering tribology as involved in bearings, the same basic principles are also demonstrated here for other machine elements such as piston rings, magnetic disk drives, viscous pumps, seals, hydraulic lifts, and wet clutches. InthissecondeditionofAppliedTribologyallthechapterswereupdatedtoreflectrecent developments in the field. In addition, this edition contains two new chapters: one on the fundamentals of seals and the other on monitoring machine behavior and lubricants, as well as bearing failure analysis. These topics are of considerable interest to the industry practitioners as well as students and should satisfy the needs of the tribology community at large. Computer solutions for basic fluid film and energy relations from the first edition have been extended to seal performance. New developments in foil bearings are reviewed. For ballandrollerbearings,conditionsenablinginfinitefatiguelifearecoveredalongwithnew ASME and bearing company life and friction factors. Properties of both mineral and synthetic oils and greases are supplemented by an update onthegreatlyextendedservicelifewithnewGroupIIandGroupIIIseverelyhydrocracked mineraloils.Similarpropertyandperformancefactorsaregivenforfull-filmbearingalloys, fordryandpartiallylubricatedbearings,andforfatigue-resistantmaterialsforrollingelement bearings. Gas properties and performance relations are also covered in a chapter on gas bearing applications for high-speed machines and for flying heads in computer read–write units operating in the nanotribology range. Problemsatthecloseofeachchapteraidinadaptingthebookasatextforuniversityand industrialcourses.Manyoftheseproblemsprovideguidelinesforsolutionofcurrentdesign and application questions. Comprehensive lists of references have been brought up to date with 145 new entries for use in pursuing subjects to greater depth. Both SI and traditional British inch-pound-second units are employed. Units in most common use are generally chosen for each section: international SI units for ball and roller bearingdimensionsandforscientificandaerospaceillustrations,traditionalBritishunitsfor oil-film bearings in industrial machinery. Many analyses are cast in dimensionless terms, enabling use of either system of units. Conversion factors are tabulated in two appendices, and guidelines for applying either system of units are given throughout the book. xii Preface Theauthorsareindebtedtopastcoworkersandstudentsfortheirparticipationindevelop- ingtopicsandconceptspresentedinthisbook.Comprehensivebackgroundinformationhas beenassembledbytheauthorsfromtheircombined80yearsoflaboratory,industrial,teaching,andconsultingexperience.Muchofthisbackgroundhasbeendrawnfromwellover250 technicalpublications,mostoftheminarchivalliterature.Thesesanddissertationprojectsat Ohio State University, the University of Pittsburgh, Southern Illinois University, Louisiana State University; and the Pennsylvania State University; numerous industrial projects at the Center for Rotating Machinery at Louisiana State University; four tribology handbooks organized and edited for the Society of Tribologists and Lubrication Engineers; and a 1957 book Bearing Design and Application coauthored with D. F. Wilcock. This book is intended (1) for academic use in a one-semester senior engineering elective course, (2) for a graduate-level course in engineering tribology and (3) as a reference book forpracticingengineersandmachinedesigners.Itishopedthattheseuseswillprovidepaths for effectively designing, applying, and lubricating bearings and other machine elements while taking advantage of concepts in tribology—the developing science of friction, wear, and lubrication. MMK ERB