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This paper is a broad survey of the lubrication of rolling-element bearings. Emphasis is on the critical design aspects related to speed, temperature, and ambient pressure environment. Types of lubrication including grease, jets, mist, wick, and through-the-race are discussed. The paper covers the historical development, present state of technology, and the future problems of rolling-element bearing lubrication.
Since the Soviet Union launched Sputnik 1 in 1957, the extent and direction of the Soviet space effort have remained unclear. The present book penetrates the secrecy-shrouded Soviet space program, telling not only of its unpublicized disasters, but giving credit to its recent successes as well. The book discusses Khrushchev's sponsorship of early space successes as political surprises, and the incident in October 1960, when forty rocket engineers died in a launch-pad disaster. The life story of Sergei Korolev, the chief designer, is discussed, as well as the 'race to the moon' in the late 1960s. The Apollo-Soyuz expedition and other more recent space-station missions are presented.
Machines were constructed and evaluated for burnishing polytetrafluoroethylene on balls for use in the high pressure oxygen turbopump (HPOTP). The most positive performance was obtained with single-ball burnishing, but one technique for burnishing three balls simultaneously holds promise. Evaluations of the coatings in a HPOTP bearing of earlier design (employed smaller diameter balls) showed very little life enhancement before high torque and ball and race wear initiated. Other coating techniques, such as molybdenum disulfide combined with PTFE transfer films, hold promise for providing the more durable quantities of solid lubricant needed for the bearings.
A dual momentum vector control concept, consisting of two counterrotating rings (each designated as an annular momentum control device), was studied for pointing and slewing control of large spacecraft. In a disturbance free space environment, the concept provides for three axis pointing and slewing capabilities while requiring no expendables. The approach utilizes two large diameter counterrotating rings or wheels suspended magnetically in many race supports distributed around the antenna structure. When the magnets are energized, attracting the two wheels, the resulting gyroscopic torque produces a rate along the appropriate axis. Roll control is provided by alternating the radiative rotational velocity of the two wheels. Wheels with diameters of 500 to 800 m and with sufficient momentum storage capability require rims only a few centimeters thick. The wheels are extremely flexible; therefore, it is necessary to account for the distributed nature of the rings in the design of the bearing controllers. Also, ring behavior is unpredictably sensitive to ring temperature, spin rate, manufacturing imperfections, and other variables. An adaptive control system designed to handle these problems is described.
The programmable pilot oriented display (P-POD), a multiprocessor based flight information processing and display unit, is discussed. Communication protocols between the three Z-80 processors inside P-POD are reviewed. The interface between the video processor, P2, and the main processor, P1, was tested. Hardware and software were revised. Data flow between P1 and P2 is illustrated. While running diagnostic routines to exercise the P1/P2 interface at maximum speed an intermittent failure was observed. A check of possible noise sources or race conditions in the hardware did not reveal the source of this failure. Possible software timing problems were also fully investigated. To eliminate the effects of this type of failure a performance monitor routine was used to detect these occasional failures and correct them. The data transmission cycle between P1/P2 is either allowed to continue normal operation or is re-initialized and restarted when an error is detected.
The effect of bearing thermal growth on the effectiveness of the bearing preload springs on the space shuttle main engine high pressure oxygen turbopump (SSME HPTOP) were examined. The SSME HPTOP turbine end bearings, preload spring, and bearing mounting design were evaluated relative to spalling, excessive ball wear, possible thermal problems, and cage delamination. The magnitude of the thermal stresses required to cause high levels of ball wear were calculated. Plots of maximum sheer stress and maximum reversing shear versus the axial load for the 57 mm SSME HPTOP bearing were created. A plot of the bearing thermal growth versus preload spring deflection was generated. It was determined that metallic wear, rather than thermal growth, caused enlargement of the contact zone between ball and races, that high fatigue-inducing shear stresses are generated under increased loads, and that at temperatures between 100 and 150 deg C, the springs bottom out and very high loads are developed in the bearing. Allowance for adequate spring movement after assembly is recommended.
Technique for reworking stock bearings saves time and produces helicopter-rotor bearings ground more precisely. Split tapered ring at one end of threaded bolt expands to hold inside of inner race bearing assembly; nut, at other end of bolt, adjusts amount of spring tension. Piece of hardware grasps bearing firmly without interfering with grinding operation. Operation produces bearing of higher quality than commercially available bearings.
Parametric tests were conducted with 35mm bore, angular contact ball bearings with either a single or double-outer-land-guided cage. The bearings were either lubricated by oil jets or employed inner ring lubrication. Outer ring cooling was added in selected tests. Test conditions were a radial load of 222 N (50 lb) and/or a thrust load of 667 N (150 lb), shaft speeds to 72,000 rpm, and an oil inlet temperature of 394 K (250 F). Lubricant flow to the bearing ranged rom 300 to 1900 cc/min (0.08 to 0.50 gal/min). All bearings were successfully run at speeds to 2.5 million DN. Increasing the lubricant flow decreased bearing ring temperatures but increased bearing power loss. The power loss and race temperatures of a jet lubricated bearing with double-outer-land-guided cage were always higher than those of the single-land-guided-design at similar test conditions. The lowest bearing operating temperatures were achieved when inner ring lubrication and outer ring cooling were combined. Cage slip of a double-outer-land-guided cage was approximately twice that of a single-outer-land-guided cage.
The operating characteristics of large diameter rolling-element bearings in the ultra high speed regimes expected in advanced turbine engines for high performance aircraft were investigated. A high temperature lubricant, DuPont Krytox 143 AC, was evaluated at bearing speeds to 3 million DN. Compared to the results of earlier, similar tests using a MIL-L-23699 (Type II) lubricant, bearings lubricated with the high density Krytox fluid showed significantly higher power requirements. Additionally, short bearing lives were observed when this fluid was used with AISI M50 bearings in an air atmosphere. The primary mode of failure was corrosion initiated surface distress (fatigue) on the raceways. The potential of a case-carburized bearing to sustain a combination of high-tangential and hertzian stresses without experiencing race fracture was also investigated. Limited full scale bearing tests of a 120 mm bore ball bearing at a speed of 25,000 rpm (3 million DN) indicated that a carburized material could sustain spalling fatigue without subsequent propagation to fracture. Planned life tests of the carburized material had to be aborted, however, because of apparent processing-induced material defects.
The values of inner and outer race temperature, cage speed, and heat transferred to the lubricant or bearing power loss, calculated using the computer programs Shaberth and Cybean, with the corresponding experimental data for the large bore ball and roller bearings were compared. After the development of computer program, it is important that values calculated using such program are compared with actual bearing performance data to assess the programs predictive capability. Several comprehensive computer programs currently in use are capable of predicting rolling bearing operating and performance characteristics. These programs accept input data of bearing internal geometry, bearing material and lubricant properties, and bearing operating conditions. The programs solve several sets of equations that characterize rolling element bearings. The output produced typically consists of rolling element loads and Hertz stresses, operating contact angles, component speed, heat generation, local temperatures, bearing fatigue life, and power loss. Two of these programs, Shaberth and Cybean were developed.
Parametric tests were conducted with 35mm bore, angular contact ball bearings with either a single or double outer and guided cage. The bearings were either lubricated by oil jets or employed inner ring lubrication. Outer ring cooling was added in selected tests. Lubricant flow to the bearing ranged from 300 to 1900 cc/min. All bearings were successfully run at speeds to 2.5 million DN. Increasing the lubricant flow decreased bearing ring temperatures but increased bearing power lines. The power loss and race temperatures of a jet lubricated with double outer land guided cage were always higher than those of the single land guided design at similar test conditions. The lowest bearing operating temperatures were achieved when inner ring lubrication and outer ring cooling were combined. It is found that cage slip of a double outer land guided cage is approximately twice that of a single outer land guided cage.
Pivoting slips are calculated for the ball-race and ball-ball contacts in a retainerless bearing. The calculation is kinematic, ignoring all inertial loadings. Pure spin and uniform precession of the balls are considered. Pivoting slip magnitudes are compared with several other kinds of slip which were previously reported in an R4 size bearing.
Endurance tests with ball bearings made of corrosion resistant bearing steel which resulted in fatigue lives much lower than were predicted are discussed. Metallurgical analysis revealed an undesirable carbide distribution in the races. It was shown in accelerated fatigue tests in the RC rig that large, banded carbides can reduce rolling element fatigue life by a factor of approximately four. The early spalling failures on the bearing raceways are attributed to the large carbide size and banded distribution.
The Shaberth bearing analysis computer program was developed for the analysis of jet engine shaft/bearing systems operating above room temperature with normal hydrocarbon lubricants. It is also possible to use this tool to evaluate the shaft bearing systems operating in cryogenics. Effects such as fluid drag, radial temperature gradients, outer race misalignments and clearance changes were simulated and evaluated. In addition, the speed and preload effects on bearing radial stiffness was evaluated. The Shaberth program was also used to provide contact stresses from which contact geometry was calculated to support other analyses such as the determination of cryogenic fluid film thickness in the contacts and evaluation of surface and subsurface stresses necessary for bearing failure evaluation. This program was a vital tool for the thermal analysis of the bearing in that it provides the heat generation rates at the rolling element/race contacts for input into a thermal model of the bearing/shaft assembly.
The research program begun by NASA in 1959 in order to investigate the projected temperature and speed requirements of large bore ball and roller bearings was expanded in the 1970s to include tapered roller and small bore bearings. In the course of the program, bearing speeds as high as 3 million DN and 2.4 million DN, respectively, were achieved for ball and tapered roller bearings with fatigue lives exceeding those common in commercial aircraft. The computer analysis of rolling element bearings operation have yielded reasonably accurate performance predictions for speeds up to 3 million DN. It was found that under-race bearing lubrication improved operational performance over that achieved with conventional jet lubrication methods at high bearing speeds.
The source code for the SPICE 2 program was deblocked in order to isolate and compile the subroutine in an effort to provide a software simulation of discrete and combinatorial electronic components. Incompatibilities between the UNIVAC 1180 FORTRAN and the Sigma V CP-V FORTRAN 4 were resolved. The SPICE 2 model is to be used to determine gate and fan-out delays, logic state conditions, and signal race conditions for transistor array elements and circuit logic to be patterned in the (SPI) 7101 CMOS silicon gate semicustom array. The simulator is to be operable from the CP-V time sharing terminals.
The low service life of the high pressure oxygen turbopump (HPOTP) bearings used in the space shuttle main engine was examined by use of the Battelle "BASDAP' bearing computer stability model. The dynamic instability of the bearing cage resulted in excessive wear and eventual failure of the unit. By maintaining a cage/race clearance of no more than 0.25 millimeters (0.010 inches), ball/pocket clearance of no less than 0.54 millimeters (0.025 inches), dynamic balancing of the cages, and maintaining adequate lubricant films between the balls and races, cage instability and subsequent bearing degradation can be reduced.
A Mode II test specimen was developed which has potential application in understanding phemonena associated with mixed mode fatigue failures in high performance aircraft engine bearing races. The attributes of the specimen are: it contains one single ended notch, which simplifiers data gathering and reduction; the fatigue crack grous in-line with the direction of load application; a single axis test machine is sufficient to perform testing; and the Mode I component is vanishingly small.