WAUKESHA BEARINGS

Rolls-Royce
Education Workshop

Rich Fischer
Antigo, WI
September 15, 2004

WAUKESHA BEARINGS
Topics

Bearing Principles and Operation

Types of Bearings
Sleeve and Tilting Pad Bearings
Thrust Bearings
Bearing Materials
Damage Analysis
Questions

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Bearing Types
³ Bearing: a machine part that allows relative motion
(rotating or sliding) between two surfaces with
minimal friction.
W W

U U
Shear
Layer

Rolling Element Sliding Surface

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Bearing Types
Bearings

Rolling Element Sliding Surface Approaching Surface

Ball Boundary Squeeze Film

Roller
Dry
Gear Mesh
Mixed Film

Full Film

Hydrodynamic

Hydrostatic

Hybrid

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Bearing Type Comparison
Hydrodynamic Rolling Element
Bearing Bearing
Life Expectancy Infinite (Theory) Limited L10
Impact Loads Excellent Poor
Damping Excellent Poor
Speed Limitations Approaches Limited to DN
Burst Limit
Noise Quiet Can Be Noisy
Start-up Torque High Low
Operating Friction Low Low
Lubrication Pressure Fed Simple
Cost Low to High Low to Moderate
Position Control Fair Good
Assembly/Repair Easy to Difficult Difficult
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Three Phases of Sliding Surface Lubrication

Mixed
Friction

Boundary Mixed
Full Film
Boundary

Hydrodynamic

Minimum Friction

Speed
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Hydrodynamic Fluid Film Bearings

A Hydrodynamic Fluid Film Bearing is a bearing where

the two surfaces are separated by a thin film of
lubrication. No contact of the surfaces takes place
except during start-up and shutdown.

Journal Bearing Thrust Bearing

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Hydrodynamic Bearing Primary Functions

³ Control Rotor Position

³ Balance Forces on System

³ Provide Damping

³ Sacrificial Component

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Control Rotor Position & Forces

Two Types

Axial

Radial

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Hydrodynamic Bearing Requirements

³ Requirements for Film Development:

1 Viscous Fluid
2 Relative Motion
3 Converging Geometry

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Hydrodynamic Bearing Requirements

VISCOUS
FLUID ROTOR

Negative Pressure
(Diverging Flow)

Positive Pressure
(Converging Flow)

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Hydrodynamic Bearing Requirements -
Relative Motion

U = VELOCITY
ROTOR

V1 = U
Vavg = (1/2) U
V2 = 0

BEARING

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Topics

Bearing Principles and Operation

Types of Bearings
Radial - Sleeve and Tilting Pad Journal Bearings
Axial - Thrust Bearings
Bearing Materials
Damage Analysis
Questions

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Journal Bearing Nomenclature

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Journal Bearing Nomenclature - Specific Load

³ L = Pad Length

³ D = Bearing Bore
L
D ³ Bearing Area = L x D

³ Specific Load = Load/Area

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Journal Bearing Nomenclature
0 = Attitude Angle
e = Eccentricity
e

0 Minimum Film Thickness

Lin
eo
fC
Bearing ent
e rs
Center Line
Journal Center Line
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Forces on Journal

Inertial

Damping

Load/Weight Resultant Film Force

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Forces on Journal

Inertial

Damping

Weight Resultant Film Force

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Products – Sleeve Bearings
³ Varying Lobe Geometry

³ Varying # of Lobes

³ Material - Bronze, Steel/Babbitt, etc…

³ Typical Size - from 0.75” (20mm) to 30.00”

(760mm)

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Sleeve Bearings – Axial Groove
³ Found in relatively slow
speed rotating machinery

³ Typically 2 to 4 axial
grooves

³ Cylindrical Bore

³ Suitable for bi-directional

rotation

³ Primary design variable is

clearance

³ Typical size - from 0.75”

(20mm) to 30.00”
(760mm)

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Sleeve Bearings – Elliptical Bore
³ Found in medium speed
rotating machinery

³ Basically 2 axial grooves

with the vertical clearance
slightly tighter than the
horizontal

³ Suitable for bi-directional

rotation

³ Primary design variables

are clearance and
preload

³ Adds stability over a plain

cylindrical bore

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Sleeve Bearings – Taper Land Bore
³ Found in high speed
rotating machinery with
light rotors

³ Most common is a 3 taper

land design

³ Uni-directional rotation

³ Primary design variables

are clearance, taper
length and depth

³ Adds stability over a plain

cylindrical bore

³ Less load capacity

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Sleeve Bearings – Pressure Dam Bore
³ Found in medium to high
speed rotating machinery

³ Most common is a 2 axial

grooves, pocket in one
pad and the other plain

³ Uni-directional rotation

³ Primary design variables

are clearance, pocket
dimensions

³ Adds stability over a plain

cylindrical bore

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Sleeve Bearings – Offset Half
³ Found in medium to high
speed rotating machinery

³ 2 axial grooves

³ Uni-directional rotation

³ Primary design variables

are clearance and offset

³ Adds stability over a plain

cylindrical bore

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Products – Tilting Pad Journal

³ Varying Pivot Styles

O Plain Back, Button Back,
Integral Rib, Ball & Socket
³ Varying # of Pads
³ Material - Bronze, Steel/Babbitt,
CrCu/Babbitt, etc…
³ Typical Size - from 0.75” (20mm)
to 25.00” (635mm)

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Journal Bearing Nomenclature - Components

Pad

Shell

End Seal

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Journal Bearing Nomenclature - Arc Angle
³ Pad Arc Length is the Distance from Leading Edge to Trailing
Edge

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Journal Bearing Nomenclature - Offset Pivot

³ Pivot Offset is the Location of the Pivot as a Percentage

of the Pad Arc Length

30° 39°
60° 60°

50% Offset 65% Offset

(Center Pivot)

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TPJ Nomenclature - Load Orientation
Load Between Pads Load On Pad

Rotor Weight Rotor Weight

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TPJ Nomenclature - Preload

Rj = Shaft Radius
Rb = Bearing Set Radius
Rp = Pad Machined-in Radius
Rj
Cb = Rb - Rj = Bearing Set Clearance
Rp Rb Cp = Rp - Rj = Pad Clearance
m = 1 - (Cb / Cp) = Preload

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TPJ Nomenclature - Preload Example

Example:
Rj = 1.500” (38.10 mm)
Rb = 1.502” (38.15 mm)
Rp = 1.503” (38.18 mm)
Rj Cb = 0.002 (Radial) (0.051 mm)

Rp Rb
Cp = 0.003 (Radial) (0.076 mm)
m = 1- (0.002 / 0.003)
m = 0.33

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Tilting Pad Film Forces

Rotor Weight

Resultant Force

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Different Bearing Designs and Features
THE RELA TIV E PERFORMA NCE CHA RATERISTICS OF BEARINGS FO R HI GH SPEED S HAFTS
R esi stan c e Acc ep ta nc e
to Lo ad of R ela ti ve
C ap aci ty
Sti ffne ss Damp i ng Advantages Disadvantages Applications Us age
Hal d Spe ed R ot at in g C ost
Bearing Type Wh irl Lo ad

z Sim pl e to i nst al l
Pron e to h al f sp ee d
wh irl with lig h t All ro ta tin g
Plain Bore z z z z an d l in e u o lo a d an d may
ma ch in es, g ear- Wi de
Two A xial z z z z z { ma ch in e req u ire ve ry l o w b ox es an d scre w
Groove z le n gt h/ d iam ete r co mp resso rs

z rat io

z B est for ro ta ti ng R eq ui res h i gh o il B lo wers, Qu i ll

Plian Bore
Circumferential z z z z z lo a d. Sim pl e su pp l y pres sure. sh aft ste ad y

z z z z { to in sta ll an d l in e Pron e to h al f sp ee d b eari ng s, so me M od era te

z z
Single Groove wh irl with lig h t g earb o x
u p mac hi ne
b eari ng s
z
lo a d

z z z z { Sim pl e to i nst al l Large t urb in es

z z
Lo w st iffne ss i n
Lemon Bore
z z z z z
an d l in e u p h ori zo nt al and el ec tric al Wi de
{
machi nes. Pumps,

z z z ma ch in e d irec ti on
gea rbo xes

z z z z
Lemon Bore
z z z z z { Sim pl e to i nst al l
an d l in e u p
Lo w st iffne ss i n
h ori zo nt al
La rg e tu rbi n es
an d el ec tric al M od era te
with Bedded z z z z { ma ch in e d irec ti on ma ch in es.
Arc z
z z z z Hig h l ub ric an t Tu rbi n es,p u mp s,

z z z z z { p um pi ng a ct io n No t su i tab l e fo r el ec tric
Inc reasi n g
z z
Offs et H alves g iv es lo w rev erse rot at io n ma ch in es,
z z z z z {
o pe rati n g co mp resso rs,
z z z z
te mp erat ure s g earb o xe s

z z { Inh e re nt ly m ost Piv o ts li ab le to All ro ta tin g

Tilting Pad z z z z z
st ab le o f al l
frett in g wit h ma ch in es, Inc reasi n g
z z z z z {
b eari ng s. Ada pt s t o
rot at in g o r h ori zo nt al
z z z
ch an g in g lo a d d yn am ic lo ad o r ve rti cal
{
co n di ti o ns
z Used m ain l y in
z z
Lo w l oa d cap a cit y Sma ll tu rbi n es,
Four Lobe z z z z z { sma ll si zes as a
th i ck wal l fl an g ed
d ue t o fo u r co mp resso rs,
z z z z z { b eari ng wi th
g ro o ve s a nd l arg e
lo b e cle aran ce s
b lo wers,
p um ps
Wi de
ta p er l an d th rust
fac es
zzzzz v ery h ig h
Perfo rm an ce rati n g: z lo w R ela ti ve c ost : {l o w {{ { h i gh

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Design Options for Reducing Temperature
Expanding Traditional Operating Limits (Surface Temperature and
Pressure)
³Use Directed Lubrication
³Offset Pivots
³Number of Pads
³Use Cu/Cr backing material
³Axial Aligning
³Use special surface materials:
Q White-metal up to 266° F (130°C)
Q Aluminium alloys up to 320° F (160°C)
Q Copper alloys up to 356°F (180°C)
Q Peek based polymer up to 482°F (250°C)
Q Ceramics up to 716°F (380°C)

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Design Options to Influence Rotor Dynamics

³ TPJ Bearing Stiffness and Damping are “Tuned” to the

Customer’s System
³Number of Pads
³Pad Orientation

³Clearance

³Preload

³Pad Length

³ Small Changes in Bearing Clearance can Dramatically

Influence the Rotor Dynamics of the System
³ BearingClearance Controlled by Manufacturing
and Design Processes

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WBC Bearing Designs
–Reduce Affect of Misalignment
³ Axial Aligning –Keep Film Pressure and Pad Temperature Low

–Increase Capacity
³ Cr-Cu –Keep Film Pressure and Pad Temperature Low

–Control Rotor Dynamics

³ Tight Tolerances –Sensitive Machinery
–Reduce Pivot Wear
³ Surface Finish –Control Min. Allowable Film Thickness
–Looks Good!
–Used to “Tune” Bearing K & C
³ Number of Pads –Control Rotor Dynamics

–Used in Evacuated Cavity

³ Direct Lube –Reduces Power Losses

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Topics

Bearing Principles and Operation

Types of Bearings
Radial - Sleeve and Tilting Pad Journal Bearings
Axial - Thrust Bearings
Bearing Materials
Damage Analysis
Questions

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Thrust Bearing Nomenclature

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 ~
Products – Non-Equalizing Thrust

³ Can have tilting pads with varying pivot

styles
³ Button Back, Integral Rib

³ Varying # of Pads and OD or ID

³ Material - Steel/Babbitt, CrCu/Babbitt,
Bronze, etc…
³ Straight or Compound Tapers
³ Size - from 1.25” (32mm) to 60.00”
(1525mm)

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Products – Tilting Pad Thrust ~

Equalizing Style
³ Varying Pivot Styles
³ Button Back, Integral Rib

³ Varying # of Pads and OD or ID

³ Hyfilm Equalization & Standard
³ Material - Steel/Babbitt,
CrCu/Babbitt, Polymer, etc…
³ Retained & Non-retained Pads
³ Typical Size - from 1.25” (32mm) to
60.00” (1525mm)

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TPT- Bearing Metal Temperature Test Results ~

240

230
.5, Steel
220
Max Pad Temp (F)

210
.5, Cr-Cu
Cr-Cu
200 .7, Steel
190
.7, Cr-Cu
Cr-Cu
180

170

160
1,000 2,000 3,000 4,000 5,000 6,000
Speed (rpm)

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Thrust Bearing Nomenclature - Components ~

Lower Leveling Thrust Pad

Link

Upper Leveling
Link

Retainer

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Thrust Bearing Nomenclature - Self Leveling ~

THRUST PAD
SUPPORT DISC

COLLAR

RETAINER
OIL FEED SLOT
UPPER LEVELING LINK LOWER LEVELING LINK

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Thrust Bearing Nomenclature – WBC Hyfilm

THRUST
PAD THRUST PAD SUPPORT RIB

COLLAR

LEVELING
BASE LOWER DISC PIVOT PIN
RING LINK OIL FEED HOLE

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Thrust Bearing Nomenclature - Specific Load ~

L
Aspect Ratio = B / L
B = Pad Circumferential
Length at Mean Diameter B
L = Pad Radial Length
Pad Area = Actual Area
Total Thrust Bearing Area = Actual Area x Number of Pads
Specific Load = Load / Total Thrust Bearing Area

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Hydrodynamic Pressure Profile ~

Peak Pressure is 2x to 3x greater than

average pressure 2
300 psi (2 N/mm )

300 PSI

700 PSI

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Thrust Bearing Lubrication ~

³ Flooded Cavity
³ Flow Controlled with Inlet or Discharge Restriction

³ Oil Exits from Top of Thrust Cavity

³ Cavity Full of Oil

³ Evacuated Cavity
³ Drain Located at Bottom of Cavity

³ Flow Controlled at Bearing (Directed Lubrication)

³ No Standing Oil in Cavity

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TPT - Flooded vs. Evacuated Cavity ~

Flooded Cavity Thrust Losses

10.5"; 350 psi

70

60

50
Losses (hp)

These losses go away

40 with evacuated cavity!

30

20

10

0
50 100 150 200 250

Mean Sliding Velocity (ft/sec)

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Products – Special Features ~

³ DL Lubrication, Equalizing,
Tilting Pad Thrust Bearing with
Hydrostatic Lift

³ Pocket Feed, Equalizing, Tilting

Pad Thrust Bearing with
Hydrostatic Lift and offset pad
pivots

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 ~
Products – Combination Bearings

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Topics
Waukesha Bearings
Bearing Principles and Operation
Types of Bearings
Radial - Sleeve and Tilting Pad Journal Bearings
Axial - Thrust Bearings
Bearing Materials
Damage Analysis
Questions

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Sacrificial Component

³ Soft “White Metal”

³ Helps Bearing be Sacrificial during Upsets

(Weakest Link)

³ But Has Characteristics of:

³ Conformability

³ Embeddability

³ Which Makes it Forgiving and Rugged!

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Bearing Material
ASTM B-23 Grade 2 Tin Based Babbitt

Tin (Sn) 89.0 %

Antimony (Sb) 7.5 %
Copper (Cu) 3.5 %
Yield Pt 68F (psi) 6100
Yield Pt 212F (psi) 3000
Brinell Hardness 68F 24.5
Brinell Hardness 212F 12.0
Melting Point (F) 466
Pouring Temp (F) 795

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Yield Strength Verses Temperature
ASTM B-23 Grade 2 Babbitt

psi)
Yield Strength (1000 psi)
12
10
Compression
8

4
Tension
2

0
0 50 100 150 200 250 300 350
Temperature (F)

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Material Options
³ A Full Range of Bearing Materials

Materials
Ceramics for process
lubrication (380 C)
CuPb
Load Capacity

(180 C)
Polymers tuned to
application ( 250 C)

AlSn (160 C) Magnetics for the

ultimate non-material !

Babbitt (130 C)

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Products – Polymer Bearings
³ A tilting pad axial
bearing with polymer
lining in a bore hole
pump, typically a mile
underground.
³ Temperature can be
250 C (482 F) with a
load 2 to 3 times the
normal Handbook limits.

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Products – Ceramic Bearings

³ Process lubricated
(i.e. seawater)

³ Temperature as high
as 380 C (716 F)

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Products – Magnetic Bearings

³ No mechanical contact
³ No oil contamination of process
fluid
³ Capability to operate in process
fluid
³ No lubrication system
³ Wide temperature range
³ High speed capability
³ Low energy consumption
³ Controllable rotor dynamics
³ Vibration attenuation
³ Improved machine diagnostics
³ Increased reliability/availability
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Topics
Waukesha Bearings
Bearing Principles and Operation
Types of Bearings
Radial - Sleeve and Tilting Pad Journal Bearings
~ Axial - Thrust Bearings
Bearing Materials
Damage Analysis
Questions

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When Things Go Wrong

Misalignment
Babbitt Fatigue and Bad Bond
High Load and/or High Temperature
Pivot Stress and Wear

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Effect of Shaft Misalignment
Peak Pressure 2x to Peak Pressure 6x to
3x Ave. Pressure 7x Ave. Pressure

Metal Metal
Temp Bearing Temp Bearing
= 200F = 300F
300 psi

700 psi peak

2000 psi peak
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Thrust Bearing Nomenclature - Self Leveling

THRUST PAD
SUPPORT DISC

COLLAR

RETAINER
OIL FEED SLOT
UPPER LEVELING LINK LOWER LEVELING LINK

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Sleeve Bearing Misalignment

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Sleeve Bearing Misalignment

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Combination Bearing – Wiped Tilting Pads

Overload of Tilting
Pads

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Combination Bearing – Over Heated Sleeve Brg

Over heating of
sleeve bearing

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Combination Bearing – Heat damage on taper lands

Over heating of taper land bearing

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Babbitt Fatigue

Journal
Cracks Loose Babbitt Bearing Surface
Clearance
Babbitt
Bond Line

Backing Material

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Thrust Bearing Babbitt Fatigue

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High Load / Lack of Lubrication

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Moderate Scoring

Scoring cause by dirt in oil

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Moderate Scoring

Scoring cause by dirt in oil

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Tilting Pads Wiped

Note that all pads are wiped

Wiped and seized on rapid
start-up

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Electrical Discharge

Motors and Generators

Hemispherical pitting and
scoring

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Faceting

Many times only cosmetic

Due to thermal cycling

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Pivot Wear

Line Contact Pad

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WBC
Questions?

WAUKESHA BEARINGS