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CHAPTER – 1
INTRODUCTION
From time to time more attention had given for optimum selection of
bearing type and determining the required characteristics for pump applications.
Pump design engineers are often faced with a difficult question: “How can I
choose among thousands of different bearing types for my application?” In order
to design the optimum bearing arrangement for pumps, the following aspects
have to be considered, magnitude and direction of applied loads, available space,
rigidity/misalignments, arrangement of shaft and bearing position, bearing life
expectation, precision, running accuracy, running noise, operating environment,
lubrication, mounting and maintenance and cost efficiency.
As an important component, the radiator coolant pump bearing is widely
used in the auto engine cooling system. Unfortunately, the radiator coolant pump
bearing itself is often subjected to premature failure because of improper
structure design, poor lubrication or sealing, unreasonable allocation of the
applied loads on two element rows of the bearing and so on. At the present time,
there are many researches on auto water pump bearing lubrication, structures and
material performances, but only few on the bearing loads as well as the influence
of the load variations on the bearing life. Load determination and life prediction
calculation of the bearing are the premises of a good bearing design and a
reasonable working condition matching, and yet it is one of difficulties in the
practical application.
1.1 RADIATOR COOLANT PUMP
A radiator coolant pump is a necessity for the forced circulation type of
engine cooling system. The pump is mounted at the front end of the engine and is
driven from the crankshaft by means of a V-belt. The main parts of the coolant
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effectiveness of rolling bearings in modern engineering applications, a firm
understanding of how these bearings perform under varied and often extremely
demanding conditions of operation is necessary.
Rolling bearings are used in a wide range of applications. When selected
and applied properly, they can operate successfully over a long period of time.
Rolling friction is lower than sliding friction; therefore, rolling bearings have
lower friction energy losses as well as reduced wear in comparison to sliding
bearings. When a rolling-element bearing is in operation, the rolling contacts are
subjected to alternating stresses at high frequency that result in metal fatigue. At
high speed, the centrifugal forces of the rolling elements, high temperature (due
to friction-energy losses) and alternating stresses all combine to reduce the
fatigue life of the bearing. The fatigue life of a rolling bearing is a function of the
magnitude of the oscillating stresses at the contact. If the stresses are low, the
fatigue life can be practically unlimited.
Figure 1.2 (a) Ball Bearing (b) Roller Bearing
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1.3. TYPES OF ROLLING BEARING FOR PUMPS
The different types of rolling bearing are provided in the Table 1.1. The
different bearings types have their characteristics and therefore are suitable for
different applications. The following will provide details about some standard
bearing types commonly used in pump applications.
Table 1.1 Types of Rolling Bearing
BALL BEARING
Radial ball bearingSingle row deep groove
Double row deep groove
Angular-contact bearing
Single row angular-contact
Double row angular-contact
Self aligning double row
Split inner ring
Thrust ball bearing ---
ROLLER BEARING
Radial roller bearingsCylindrical roller
Needle roller
Taper roller bearing ---
Spherical roller bearing ---
Thrust roller bearing
Spherical roller
Cylindrical roller
Tapered roller
Needle roller
1.3.1 Cylindrical Roller Bearings
These are suitable for high radial loads and high-speed applications. Due
to separable outer and inner rings, cylindrical roller bearings enable simple
mounting and dismounting.
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The variants with one lipless ring are ideally used as floating bearings.
Single row and double-row cylindrical roller bearings are available.
1.3.2 Angular Contact Ball Bearings
Such bearings are able to accommodate high radial loads and, when
double-row or paired, high thrust loads in both directions. Angular contact ball
bearings are also suitable for high-speed operations.
1.3.3 Spherical Roller Bearings
These bearings can accommodate manufacturing and assembly
misalignments of shaft to housing, including shaft bending and deflections.
Spherical roller bearings are able to carry very high radial loads and certain axial
loads in either direction.
However, this type of bearing is not suitable for very high speeds.
Standard features such as circumferential grooves and lubricating holes in the
outer ring allow easy for lubricating again and again.
1.3.4 Deep Groove Ball Bearings
The simplest yet the most popular bearings, deep groove ball bearings can
accommodate moderate radial and axial loads and are suitable for very high
speed operations. Different variants in seals and greases are available for
different operating conditions.
Most of these standard bearings are available with various special options
– e.g. cages, clearance groups and seals – to accommodate different operating
conditions.
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The dimensions for rolling element bearings have been standardized and
can be purchased as stock items from specialist manufacturers and suppliers. The
selection of a bearing from a manufacturer’s catalogue involves consideration of
the bearing load carrying capacity and the bearing geometry. For a given bearing,
the load carrying capacity is given in terms of the basic dynamic load rating and
the basic static load rating. The various commonly used definitions for rolling
element bearing life specification are outlined.
The basic dynamic load rating C, is the constant radial load which a
bearing can endure for 1x106 revolutions without evidence of the development of
fatigue in any of the bearing components. The life of a ball bearing, L, is the
number of revolutions (or hours at some constant speed), which the bearing runs
before the development of fatigue in any of the bearing components.
Fatigue occurs over a large number of cycles of loading. For a bearing,
this would mean a large number of revolutions. Fatigue is a statistical
phenomenon with considerable spread of the actual life of a group of bearings of
a given design. The rated life is the standard means of reporting the results of
many tests of bearings. It represents the life that 90% of the bearings wouldachieve successfully at a rated load. The rated life is referred to as the L 10 life at
the rated load. The rated life, L10, of a group of apparently identical bearings is
defined as the number of revolutions (or hours at some constant speed) that 90%
of the group of bearings will complete before the first evidence of fatigue
develops.
If in Equation (1.1), P2 = C and the corresponding life L2 = 1x106, then the
life of a bearing L, with basic dynamic load rating C with a load P, is given by
Equation 1.2,
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1.6. ADVANTAGES OF ROLLING BEARING
They operate with much less friction torque than hydrodynamic
bearings and therefore considerably less power loss and friction heat
generation.
Bearing deflection is less sensitive to load fluctuation.
Combinations of radial and thrust loads can be supported
simultaneously.
Individual designs yield excellent performance over a wide load-speed
range.
Starting friction torque is only slightly greater than moving friction
torque.
They require only small quantities of lubricant for satisfactory
operation and have the potential for operation with a self-contained,
life-long supply of' lubricant.
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Qi An et all., (2012) had done their research for Load Calculation and
Life Prediction for Auto Water Pump. They have taken the water pump
bearing with one roller row (WR)-type auto water pump bearing as a research
sample, an analytical calculation method is developed to improve the accuracy
and efficiency of the current calculations for the bearing loads and life in
engineering application. The bearing load and life calculation results are
compared with those calculated by the traditional method in which the deflection
of the bearing spindle and the roller tilt are ignored. The life decrease in the auto
water pump bearing is significant due to the deflection of the bearing spindle and
it is recommended to give more attention to this deflection for the high quality of
the bearing design and calculation.
Li Zhengmei et all., (2011) examined the Influences of Eccentric
Unbalances on Loads and Life of Auto Water Pump Bearing. The life of
auto water-pump bearing is closely related to its loads which are affected by the
eccentric unbalances of rotational components in the structure system of the
bearing. However, since the bearing structure in auto water-pump is complicated,
the exact load calculations and the life prediction for this kind of bearing are
difficult. In this paper, theWR3258152 auto water-pump bearing is investigated.
The load and life calculation models for the bearing are developed with
considering the eccentric unbalances of the cooling fan and the driving wheel.
The influences of the fan and the wheel unbalances on the loads and life of the
bearing are studied. The calculation and analysis results show that the radial
loads on rolling element rows of the auto water-pump bearing fluctuate
significantly under the actions of the fan and the wheel unbalances and the
bearing life reduces regularly with the eccentric unbalances changing.
Zhang Yongqi et all., (2012) dealt with the Analysis of Stress and
Strain of the Rolling Bearing by FEA Method. Taper roller bearings are
important part of gear reducers, and their work property affects behaviour of the
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within a short period, due to cavities created on the bearing raceway.
Recommendation towards enhancement of bearing life is also suggested.
Necdet Demirhan et all., (2008) analyzed on the Stress and
Displacement Distributions on Cylindrical Roller Bearing Rings Using FEM.
Stress and displacement distributions on inner and outer rings of cylindrical roller
bearings are investigated using the finite element (FE) method. FE models are
solved by considering the interactions of steel shaft, inner ring, rollers, outer ring,
and outer cage using ANSYS. The mesh convergence rates of FE models are
investigated and the optimum number of elements is selected in the models. The
load distributions on rollers are determined. The radial, tangential, and von Mises
stresses are plotted along the inner and outer faces of the inner and outer rings.
R. Sehgal et all., (1999) had made their research on Reliability
Evaluation and Selection of Rolling Element Bearings. A procedure based on
graph theory and matrix approach has been developed for the reliability
evaluation and selection of a rolling element bearing for an application. The
reliability of the bearing is evaluated considering reliability of its elements and
their connections. This is modelled in terms of Reliability Graph of a Rolling
Element Bearing. This graph is represented by an equivalent matrix called
Rolling Element Bearing Reliability Permanent Matrix to obtain a matrix
function-Reliability Permanent Function. This function is the characteristic of
reliability of the rolling element bearing for the application. Reliability Index
( RI) of the bearing is also defined. It is a numerical measure of the bearing
reliability and is obtained by substituting reliability value of the bearing elements
and their connections in the matrix function. The paper also suggests how to
assess these reliability values to obtain the index. The proposed procedure is
useful for designers and practicing engineers for selection of an optimum bearing
for a given application.
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CHAPTER – 3
RADIATOR COOLANT PUMP BEARING
3.1 BASIC DESIGNS
In the case of coolant pump bearings, they are designed and machined to
meet the specifications and conditions required for automotive water pumps,
which are basically set to comply with customer’s requirements. Coolant pump
bearings are non-separable sealed bearings, and they can be divided into two
types depending on the kinds their rolling elements, ball/ball type and ball/roller
type. Because the load capacity of ball-roller type coolant pump bearings is a lot
higher than that of ball-ball type, they are suitable to be used when they have to
support fan couplings, or when they have to transmit high belt loads, or off-set
loads. Experienced pump designers can usually avoid problems due to bearing
overload by a combination of empirical techniques and where necessary
experimental work also been done.
A radiator coolant pump bearing is a ready-to-fit bearing unit. It
comprises a shaft that is supported by means of several rows of rolling elements
in a through hardened outer ring. Under heavier loads, water pump bearings of
the roller/ball design are used. The function can be significantly improved in the
case of this design too by a combination of a row of rollers with a three or four
point contact bearing. These bearings do not have an inner ring but instead have
raceways directly machined into the shaft. As a result, there is more space
available for the rolling elements, giving a higher load carrying capacity than in
solutions with conventional single bearings. In water pump bearings, rows ofballs and rollers can be economically combined with each other. This gives a
broad range of load carrying capacity values.
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Figure 3.1 Radiator Coolant Pump – Existing Model
Figure 3.2 Coolant Pump Bearing – Existing Model
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The use of a common outer ring for two or more rows of rolling elements
prevents misalignment defects, eliminating the risk of undesirable distortion of
the bearings. In water pump bearings, the ends of the shaft normally extend
beyond the outer ring on both sides. The length and diameter of these extended
sections can be matched to the specific application. The ready-to-fit bearing unit
is predominantly used in coolant pumps for road vehicles.
These bearings are not only used in coolant pumps, however, and are
therefore also described as integrated shaft bearings. Due to the characteristics
stated, they have a wide range of possible applications, for example in:
Fans
Tension pulleys
Vane pumps
Angle grinders.
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4.1.4 Arrangement of Shaft and Bearing Position
The arrangement of the shafts (horizontal, vertical or inclined), the shaft
and housing fits based on applied loads, positional arrangements of fixed and
floating bearings, and adjustments or preloading necessary for the bearing are a
few factors to consider.
4.1.5 Bearing Life Expectation
This is an important factor in selecting the optimal bearing types and sizes
in a given application. Customers’ requirements, cost efficiency and experience
from existing applications are just a few benchmarks.
4.1.6 Precision, Running Accuracy, Running Noise
For some applications, high precision and low noise levels are required. In
some cases, a low starting torque is essential.
4.1.7 Operating Environment
Factors such as operating temperature and characteristics of the pumping
media (abrasiveness or corrosiveness, viscosity, presence of solids, etc.) are
crucial for bearing functions. Special lubricants, cages and seals are available for
various operating environments.
4.1.8 Lubrication, Mounting and Maintenance
These factors should be considered for the entire service life of thebearings. For example, if bearings in the machines must be mounted and
dismounted regularly for inspections, separable bearing types such as cylindrical
roller bearings could be advantageous.
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4.1.9 Cost Efficiency
In general, standard bearings are more economical and readily available
due to mass production. Standard bearings with special features (such as special
grease/seals/cages, etc.) are more costly. Special bearings developed for
particular applications entail higher development and production costs, but
provide tailor-made solutions to meet the specific requirements.
4.2 DESIGNING OF COOLANT PUMP BEARING
Since, we are going to design the bearing for a coolant pump which is to
be used in a heavy vehicle. Here, we consider a single row ball and roller type
bearing. Because the load capacity of ball-roller type water pump bearings is a
lot higher than that of ball-ball type, they are suitable to be used when they have
to support fan couplings.
In Figure 4.1, the detailed input drawing for the coolant pump bearing is
given. The tolerances, bearing clearances, cages & seal dimensions and fits are
clearly mentioned.
In Figure 4.2, the input drawing for the pump bearing sleeve is provided in
detail. And in Figure 4.3, the detailed drawing of the integral bearing shaft is
given.
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Figure 4.2 Input Drawing for Bearing Sleeve
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Figure 4.3 Input Drawing for Bearing Shaft
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The bearing is designed with the help of input drawings in the CREO 2.0
version software. The various parts of bearing like sleeve, bearing shaft, rollers,
balls, cages for rollers and balls are drawn separately and assembled. The
exploded view of coolant pump bearing is shown in the Figure 4.4.
Figure 4.4 Coolant Pump Bearing Assembly – Exploded View
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4.3 DESIGNING OF COOLANT PUMP
The ball / roller type bearing is assembled with the coolant pump bearing
by removing the existing taper roller bearing. From Figure 4.5, the exploded
view of the coolant pump is shown.
Figure 4.5 Radiator Coolant Pump Assembly – Exploded View
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The detailed cross sectional view of the coolant pump bearing is shown
the Figure 4.6.
Figure 4.6 Coolant Pump Bearing Assembly – Sectional View
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The cross sectional view of the coolant pump is shown in the Figure 4.7 in
a detailed manner.
Figure 4.7 Radiator Coolant Pump Assembly – Sectional View
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comparable to the standard cast type PA 6 G, but more expensive. PA 66 has
good mechanical strength, high impact strength, good damping characteristics
and good resistance to wear. Here, we take the Young’s modulus as 2000 MPa,
Poisson’s ratio (Nu) = 0.4.
4.4.3 Nitrile Butadiene Rubber (NBR) Material
Nitrile butadiene rubber (NBR) is a family of unsaturated copolymers of 2
- propenenitrile and various butadiene monomers (1, 2 - butadiene and 1, 3 -
butadiene). Although its physical and chemical properties vary depending on the
polymer’s composition of nitrile, this form of synthetic rubber is unusual in being
generally resistant to oil, fuel, and other chemicals (the more nitrile within the
polymer, the higher the resistance to oils but the lower the flexibility of the
material). It is used in the automotive and aeronautical industry to make fuel and
oil handling hoses, seals, and grommets, since ordinary rubbers cannot be used.
Here, we take the Young’s modulus as 20 MPa, Poisson’s ratio (Nu) = 0.49.
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CHAPTER – 5
ANALYSIS OF BEARING
5.1 ASSUMPTIONS FOR ANALYSIS
The solid components are meshed with tetrahedral elements.
The material properties are considered to be linear.
Contact pairs are established at regions where ever it is necessary.
Bolt, nut & washers are not considered for the analysis.
Only structural loading is considered (i.e., thermal loads are ignored)
Pre-loads are ignored.
Shaft and coupling are considered as integral components.
Couplings are rigidly connected using Rigid Elements.
5.2 MESHED MODEL OF BEARING
SOLID185 is used for 3-D modeling of solid structures. It is defined by
eight nodes having three degrees of freedom at each node: translations in the
nodal x, y, and z directions. The element has plasticity, hyper elasticity, stressstiffening, creep, large deflection, and large strain capabilities.
Figure 5.1 SOLID 185 Homogeneous Structural Solid Geometry
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It also has mixed formulation capability for simulating deformations of
nearly incompressible elastoplastic materials, and fully incompressible hyper
elastic materials.
TARGE170 is used to represent various 3-D "target" surfaces for the
associated contact elements CONTA 174 and. CONTA 175. The contact
elements themselves overlay the solid, shell, or line elements describing the
boundary of a deformable body and are potentially in contact with the target
surface, defined by TARGE170. This target surface is discretized by a set of
target segment elements (TARGE170) and is paired with its associated contact
surface via a shared real constant set. You can impose any translational or
rotational displacement, temperature, voltage, and magnetic potential on the
target segment element. You can also impose forces and moments on target
elements.
Figure 5.2 TARGET 170 Geometry
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CONTA174 is used to represent contact and sliding between 3-D "target"
surfaces (TARGE 170) and a deformable surface, defined by this element. The
element is applicable to 3-D structural and coupled field contact analyses. The
element has the same geometric characteristics as the solid or shell element face
with which it is connected. (Contact occurs when the element surface penetrates
one of the target segment elements (TARGE170) on a specified target surface.
Coulomb friction, shear stress friction, and user-defined friction with the
USERFRIC subroutine are allowed. The element also allows separation of
bonded contact to simulate interface delamination.
Figure 5.3 CONTACT 174 Geometry
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5.2.1 Contact details
Figure 5.4 Contact Details between Ball and Inner Shaft
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Figure 5.5 Contact Details between Ball and Outer Ring
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Figure 5.6 Contact Details between Roller and Inner Shaft
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Figure 5.8 Contact Details between Ball and Cage
Figure 5.9 Contact Details between Roller and Cage
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5.2.2 Boundary Conditions
Figure 5.10 Boundary Conditions
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Figure 5.12 Loading Details – Applied
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Figure 6.6 Von Mises Stress Observed in Balls
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Figure 6.8 Von Mises Stress Observed in Outer Ring
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CHAPTER – 7
CONCLUSION
In the first phase of this project, the review of literature on the rolling
bearing, radiator coolant pump, ready to fit type of radiator coolant pump bearing
and the importance of various load acting on the coolant pump bearing have been
done. Also the general considerations in the selection and designing of a bearing
are studied. The radiator coolant pump bearing model have been designed using
CREO 2.0 software according to the inputs provided from the industry
Further in the final phase, the designed model of the radiator coolant
pump bearing has been analyzed using the ANSYS software under static loading
conditions. From the analysis results for the given loading conditions, the
allowable stress is within the limit of the material equivalent stress. Thus the
design is safe.
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