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Rolling-element bearing
Post by ffbing, 2010-6-21, Views: A rolling-element bearing is a bearing which carries a load by placing
round elements between the two pieces. The relative motion of the pieces
causes the round elements to roll (tumble) with little sliding.
One of the earliest and best-known rolling-element bearings are sets of
logs laid on the ground with a large stone block on top. As the stone is
pulled, the logs roll along the ground with little sliding friction. As
each log comes out the back, it is moved to the front where the block then
rolls on to it. You can imitate such a bearing by placing several pens or
pencils on a table and placing your hand on top of them. See "bearings"
for more on the historical development of bearings.
A rolling-element rotary bearing uses a shaft in a much larger hole, and
cylinders called "rollers" tightly fill the space between the shaft and
hole. As the shaft turns, each roller acts as the logs in the above
example. However, since the bearing is round, the rollers never fall out
from under the load.
Rolling-element bearings have the advantage of a good tradeoff between
cost, size, weight, carrying capacity, durability, accuracy, friction, and
so on.Other bearing designs are often better on one specific attribute,
but worse in most other attributes. Only plain bearings have as wide use
as rolling-element bearings.
Design
Typical rolling-element bearings range in size from 10 mm diameter to a
few metres diameter, and have load-carrying capacity from a few tens of
grams to many thousands of tonnes.
A particularly common kind of rolling-element bearing is the ball bearing.
The bearing has inner and outer races and a set of balls. Each race is a
ring with a groove where the balls rest. The groove is usually shaped so
the ball is a slightly loose fit in the groove. Thus, in principle, the
ball contacts each race at a single point. However, a load on an
infinitely small point would cause infinitely high contact pressure. In
practice, the ball deforms (flattens) slightly where it contacts each
race, much as a tire flattens where it touches the road. The race also
dents slightly where each ball presses on it. Thus, the contact between
ball and race is of finite size and has finite pressure. Note also that
the deformed ball and race do not roll entirely smoothly because different
parts of the ball are moving at different speeds as it rolls. Thus, there
are opposing forces and sliding motions at each ball/race contact.
Overall, these cause bearing drag.
There are many types of rolling-element bearings, each tuned for a
specific kind of load and with specific advantages and disadvantages. For
example:
Ball bearings use spheres instead of cylinders. Clever use of surface
tension allows balls of high accuracy to be made much more cheaply than
comparable cylinders. Ball bearings can support both radial
(perpendicular to the shaft) and axial loads (parallel to the shaft).
For lightly-loaded bearings, balls offer lower friction than rollers.
Ball bearings can operate when the bearing races are misaligned.
Caged radial cylindrical bearings
Common roller bearings use cylinders of slightly greater length than
diameter. Roller bearings typically have higher radial load capacity
than ball bearings, but a low axial capacity and higher friction under
axial loads. If the inner and outer races are misaligned, the bearing
capacity often drops quickly compared to either a ball bearing or a
spherical roller bearing.
Needle roller bearings use very long and thin cylinders. Since the
rollers are thin, the outside diameter of the bearing is only slightly
larger than the hole in the middle. However, the small-diameter rollers
must bend sharply where they contact the races, and thus the bearing
fatigues relatively quickly.
Taper roller bearings use conical rollers that run on conical races.
Most roller bearings only take radial loads, but taper roller bearings
support both radial and axial loads, and thus have some of the same
advantages as ball bearings. Taper roller bearings are used, for
example, as the wheel bearings of most cars, trucks, buses, and so on. A
disadvantage is that the tapered roller is like a wedge and thus bearing
loads try to eject the roller; the force which keeps the roller in the
bearing adds to bearing friction.
sphcriel roller bearing use rollers that are thicker in the middle and
thinner at the ends; the race is shaped to match. Spherical roller
bearings can thus adjust to support misaligned loads. However, spherical
rollers are difficult to produce and thus expensive. And, the bearings
have higher friction than a comparable ball bearing since different
parts of the spherical rollers run at different speeds on the rounded
race and thus there are opposing forces along the bearing/race contact.
Most rolling-element bearing designs are for rotating or oscillating
loads, but there are also linear bearing designs. A common example is
drawer-support hardware. Another example is a bearing for a shaft which
moves axially in a hole. Axial-motion bearings often work like the
stone-and-log example, with a pathway so rolling elements that fall off
the end are pushed around to the other end, and the load rolls on to it.
These are called recirculating bearings.
Bearing failure
Rolling-element bearings often work well in non-ideal conditions. But
sometimes minor problems cause bearings to fail quickly and mysteriously.
For example, with a stationary (non-rotating) load, small vibrations can
gradually press out the lubricant between the races and rollers or balls
(False brinelling). Without lubricant the bearing fails, even though it is
not rotating and thus is apparently not being used. For these sorts of
reasons, much of bearing design is about failure analysis.
There are three usual limits to the lifetime or load capacity of a
bearing: abrasion, fatigue and pressure-induced welding. Abrasion is when
the surface is eroded by hard contaminants scraping at the bearing
materials. Fatigue is when a material breaks after it is repeatedly bent
and released. Where the ball or roller touches the race there is always
some bending, and hence a risk of fatigue. Smaller balls or rollers bend
more sharply, and so tend to fatigue faster. Pressure-induced welding is
when two metal pieces are pressed together at very high pressure and they
become one. Although balls, rollers and races may look smooth, they are
microscopically rough. Thus, there are high-pressure spots which push away
the bearing lubricant. Sometimes, the resulting metal-to-metal contact
welds a tiny part of the ball or roller to the race. As the bearing
continues to rotate, the weld is then torn apart, but it may leave race
welded to bearing or bearing welded to race.
Although there are many other apparent causes of bearing failure, most can
be reduced to these three. For example, a bearing which is run dry of
lubricant fails not because it is "without lubricant", but because lack of
lubrication leads to fatigue and welding, and the resulting wear debris
can cause abrasion. Similar events occur in false brinelling damage.
Constraints and trade-offs
All parts of a bearing are subject to many design constraints. For
example, the inner and outer races are often complex shapes, making them
difficult to manufacture. Balls and rollers, though simpler in shape, are
small; since they bend sharply where they run on the races, the bearings
are prone to fatigue. The loads within a bearing assemble are also
affected by the speed of operation: rolling-element bearings may spin over
100,000 rpm, and the principal load in such a bearing may be centrifugal
force rather than the applied load. Smaller rolling elements are lighter
and thus have less centrifugal force, but smaller elements also bend more
sharply where they contact the race, causing them to fail more rapidly
from fatigue.
There are also many material issues: a harder material may be more durable
against abrasion but more likely to suffer fatigue fracture, so the
material varies with the application, and while steel is most common for
rolling-element bearings, plastics, glass, and ceramics are all in common
use. A small defect (irregularity) in the material is often responsible
for bearing failure; one of the biggest improvements in the life of common
bearings during the second half of the 1900s was the use of more
homogeneous materials, rather than better materials or lubricants (though
both were also significant). Lubricant properties vary with temperature
and load, so the best lubricant varies with application.
Although bearings tend to wear out with use, designers can make tradeoffs
of bearing size and cost versus lifetime. A bearing can last indefinitely
-- longer than the rest of the machine -- if it is kept cool, clean,
lubricated, is run within the rated load, and if the bearing materials are
sufficiently free of microscopic defects. Note that cooling, lubrication,
and sealing are thus important parts of the bearing design.
The needed bearing lifetime also varies with the application. For example,
Harris reports on an oxygen pump bearing in the U.S. Space Shuttle which
could not be adequately isolated from the liquid oxygen being pumped, but
all lubricants reacted with the oxygen leading to fires and other
failures. The solution was to lubricate the bearing with the oxygen.
Although liquid oxygen is a poor lubricant, it was adequate, since the
service life of the pump was just a few hours.
The operating environment and service needs are also important design
considerations. Some bearing assemblies require routine addition of
lubricants, while others are factory sealed, requiring no further
maintenance for the life of the mechanical assembly. Although seals are
appealing, they increase friction, and a permanently-sealed bearing may
have the lubricant contaminated by hard particles, such as steel chips
from the race or bearing, sand, or grit that got past the seal.
Contamination in the lubricant is abrasive and greatly reduces the
operating life of the bearing assembly.


