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Tribology Material PDF
Tribology Material PDF
UNIT 5
AIR LUBRICATED BEARINGS
UNIT 8
BEARING MATERIALS
UNIT 6
FRICTION
Written by
Challa Sai Priyatham
Kolla Chaitanya Krishna
UNIT 1
TRIBOLOGY INTRODUCTION
Tribology affects our lives to a much greater degree than is commonly realized. It is
common knowledge that the human skin becomes sweaty as a response to stress or fear. It
has only recently been discovered that sweating on the palms of hands or soles of feet of
humans and dogs, but not rabbits, has the ability to raise friction between the palms or feet
and a solid surface. In other words, when an animal or human senses danger, sweating occurs
to promote either rapid flight from the scene of danger, or else the ability to firmly hold a
weapon or climb the nearest tree.
A general result or observation derived from innumerable experiments and theories is
that tribology comprises the study of:
The practical objective of tribology is to minimize the two main disadvantages of solid to
solid contact: friction and wear, but this is not always the case. In some situations minimizing
friction and maximizing wear or minimizing wear and maximizing friction or maximizing
both friction and wear is desirable. For example, reduction of wear but not friction is
desirable in brakes and lubricated clutches, reduction of friction but not wear is desirable in
pencils, increase in both friction and wear is desirable in erasers.
LUBRICATION
Lubrication is a process of applying lubricant between two rubbing surfaces which are
in contact to each other and to carry away the heat generated by friction. It can generally be
defined as the reduction of friction by using a fluid lubricant.
TYPES OF LUBRICANTS
TYPES OF LUBRICATION
Hydrodynamic lubrication
When a fluid lubricant is present between two rolling or sliding surfaces, a thicker
pressurized film can be generated by the movement of the surfaces. The non compressible
nature of this film separates the surfaces resulting in no metal-to-metal contact. The condition
in which surfaces are completely separated by a continuous film of lubricating fluid is
commonly referred to as Hydrodynamic or Full Fluid Film Lubrication. It can be formed by
wedging the lubricant through a convergent gap with the tangential surface velocities. It often
occurs in components such as cylinders, gears and plain bearings.
Boundary Lubrication is a condition in which the lubricant film becomes too thin to
provide total separation. This may be due to excessive loading, speeds or a change in the
fluid's characteristics. In such a situation, contact between surface peaks and valleys occurs.
Friction reduction and wear protection is then provided through chemical compounds rather
than properties of the lubricating fluid. Boundary lubrication often occurs during the start-up
and shutdown of equipment or when loading becomes excessive.
Mixed Film Lubrication
Elastohyrodynamic Lubrication
This Lubrication occurs as pressure or load increases to a level where the viscosity of
the lubricant provides higher shear strength than the metal surface it supports. This regime
can occur in roller bearings or gears as the lubricant is carried into the convergent zone
approaching a contact area or the intersection of two asperities. As a result, the metal surfaces
deform elastically in preference to the highly pressurized lubricant which increases the
contact area and thus increases the effectiveness of the lubricant.
The requirements that lubricants need to satisfy generally consist of the following
Mathematically
Represents the rate of shear strain or rate of shear deformation or velocity gradient
Thus viscosity is defined as shear stress required to produce unit rate of shear strain.
The SI physical unit of dynamic viscosity is the Pascal-second (Pa-s), if a fluid with a
viscosity of one Pa-s is placed between two plates and one plate is pushed sideways with a
shear stress of one Pascal, it moves a distance equal to the thickness of the layer between the
plates in one second.
The CGS physical unit for dynamic viscosity is the poise (P), named after Jean Louis
Marie Poiseuille. It is more commonly expressed, particularly in ASTM standards, as
centipoises (cP).
Temperature variation has an opposite effect on the viscosities of liquids and gases.
The viscosity of liquid decreases with increase of temperature and viscosity of gases
increases with increase of temperature. This is due to reason that viscous forces in a fluid are
due to cohesive forces and molecular momentum transfer. In liquids the cohesive forces
predominates the molecular momentum transfer, due to closely packed molecules and with
increase of temperature the cohesive forces decreases with result of decreasing viscosity. In
cases of gases the molecular momentum transfer increases and hence viscosity increases.
For liquids
For gases
KINEMATIC VISCOSITY
The CGS physical unit for kinematic viscosity is stokes (St), named after George
Gabriel Stokes. It is sometimes expressed in terms of centistokes (CST). In U.S. usage, stoke
is sometimes used as the singular form.
The kinematic viscosity is sometimes referred to as diffusivity of momentum, because
it has the same unit as and is comparable to diffusivity of heat and diffusivity of mass. It is
therefore used in dimensionless numbers which compare the ratio of the diffusivities.
Shear viscosity
It is the ratio between the pressures exerted on the surface of a fluid, in the lateral or
horizontal direction, to the change in velocity of the fluid as you move down in the fluid (this
is what is referred to as a velocity gradient).
Volume viscosity
It is called as bulk viscosity or second viscosity; it becomes important only for such
effects where fluid compressibility is essential. Examples would include shock waves and
sound propagation. It appears in the Stokes' law (sound attenuation) that describes
propagation of sound in Newtonian liquid. Alternatively,
Extensional viscosity
A linear combination of shear and bulk viscosity, describes the reaction to
elongation, widely used for characterizing polymers. For example, at room temperature,
water has a dynamic shear viscosity of about 1.0 × 10−3 Pa-s and motor oil of about 250 ×
10−3 Pa-s.
VISCOSITY INDEX
The viscosity index (V.I) of oil is a number that indicates the effect of temperature
changes on the viscosity of the oil. Low V.I signifies a relatively large change of viscosity
with changes of temperature and high V.I signifies relatively little change in viscosity
over a wide temperature range.
The oil becomes extremely thin at high temperatures and extremely thick at low
temperatures. Ideal oil for most purposes is one that maintains a constant viscosity
throughout temperature changes. The importance of the V.I can be shown easily by
considering automotive lubricants. Oil having a high V.I resists excessive thickening when
the engine is cold and, consequently, promotes rapid starting and prompt circulation; it resists
excessive thinning when the motor is hot and thus provides full lubrication and prevents
excessive oil consumption.
The Viscosity index of an oil may be determined if its viscosity at any two
temperatures is known. Tables, based on a large number of tests, are issued by the
American Society for Testing and Materials (ASTM). These tables permit calculation of
the V.I from known viscosities. Fig below shows the viscosity chart with variation of
temperature. Different oils may have different ASTM slopes the viscosity index can be
calculated from the following formula:
VI = (L − U) / (L − H) × 100
H- Viscosity of standard 100% VI oil at 100oF
U - Viscosity of oil with unknown VI oil at 100oF
EXAMPLE PROBLEM
Table 2.2
It was proposed by Dean and Davis (1929) as an indication of an oil’s viscosity-
temperature characteristics in terms of its Say bolt viscosities at 311 K (100°F) and 372 K
(210°F). Two series of reference lubricating-oil fractions (H and L) were used for
comparison. Series H exhibited little change of viscosity with temperature while the
viscosities of series L oils exhibited large variation with temperature. Series H and L
represented, respectively, the best and worst oils available in 1929. Series H oils were
assigned a VI of 100, series L a Correspondence concerning this article should be addressed
to P. T. Cummings Value of 0. The VI of an oil under test ( T ) was calculated from the
equation
VI = (L − U) / (L − H) × 100
Where U is the kinematic viscosity at 311 K of the oil in question, L and H, respectively, are
the kinematic viscosities at 311 K of the series L and H having the same kinematic viscosity
at 372 K as the oil T. Thus, the higher the VI the less the viscosity of an oil is affected by
temperature and, therefore, the better the oil.
TYPES OF FLUID FLOWS
Steady and unsteady flow.
Uniform and non-uniform flow.
Laminar and turbulent flow.
Compressible and incompressible flow.
Rotational and irrotational flow.
One, two and three-dimensional flows.
Steady and Unsteady flow:
Steady flow is defined as that type of flow in which the fluid characteristics like
velocity, pressure, density, etc. at a point do not change with time.
Unsteady flow is that type of flow, in which the velocity, pressure or density at a
point changes with respect to time.
• Newtonian: fluids, such as water and most gases which have a constant viscosity.
• Shear thinning: viscosity decreases with the rate of shear. Shear thinning liquids are very
commonly, but misleadingly, described as thixotropic.
• Thixotropic: materials which become less viscous over time when shaken, agitated, or
otherwise stressed.
• Rheopectic: materials which become more viscous over time when shaken, agitated, or
otherwise stressed.
• A Bingham plastic is a material that behaves as a solid at low stresses but flows as a viscous
fluid at high stresses.
• A magneto rheological fluid is a type of "smart fluid" which, when subjected to a magnetic
field, greatly increases its apparent viscosity, to the point of becoming a viscoelastic solid.
VISCOMETERS
TYPES OF VISCOMETERS
Capillary Viscometers
Capillary viscometers determine viscosity through measurement of the flow rate of the
fluid travelling through a capillary tube. A capillary tube is one with a large length to
diameter ratio.
By rearranging: The user is instructed to measure the time for the fluid to
travel a specified distance and then the kinematic viscosity is calculated as:
Types of viscometers/options:
There are 3 primary types of capillary tube viscometers.
Original Ostwald
Suspended level
Reverse flow capillary viscometers
Original Ostwald The Ostwald Viscometer is one of the simplest capillary tube
viscometer. The viscometer consists of a bulb connected to a long
capillary tube. To use the viscometer one partially fills it and then
draws the fluid to the upper mark above the right side bulb. The
fluid is released to flow through the capillary tube and the time for
the upper bulb to empty is measured. Some of the problems
associated with the use of the Ostwald viscometer include the need
to keep the viscometer vertical, the requirement for a specific
volume of fluid and the effect of temperature on the viscosity
measurement.
Suspended Level Viscometers
To determine viscosity, the test liquid is loaded into the upper bulb and
then released. The liquid flowing through the capillary is separated
from the reservoir bulb at the bottom. The third tube which connects the
bottom of the capillary tube to the ambient ensures that the only
pressure difference between the top of the bulb and the bottom of the
capillary is that due to the hydrostatic pressure--i.e., the weight of the
liquid.
Rotational Viscometers
Rotational viscometers are based on the principle that the fluid whose viscosity is
being measured is sheared between two surfaces (ASTM D2983). In these viscometers one of
the surfaces is stationary and the other is rotated by an external drive and the fluid fills the
space in between. The measurements are conducted by applying either a constant torque and
measuring the changes in the speed of rotation or applying a constant speed and measuring
the changes in the torque. These viscometers give the ‘dynamic viscosity’. There are two
main types of these viscometers: rotating cylinder and cone-on-plate viscometers.
Rotating Cylinder Viscometer
The rotating cylinder viscometer, also known as a ‘Couette viscometer’, consists of
two concentric cylinders with an annular clearance filled with fluid as shown in Figure 2.13.
The inside cylinder is stationary and the outside cylinder rotates at constant velocity. The
force necessary to shear the fluid between the cylinders is measured. The velocity of the
cylinder can be varied so that the changes in viscosity of the fluid with shear rate can be
assessed. Care needs to be taken with non-Newtonian fluids as these viscometers are
calibrated for Newtonian fluids. Different cylinders with a range of radial clearances are used
for different fluids. For Newtonian fluids the dynamic viscosity can be estimated from the
formula
F IGURE shows Schematic diagram of a rotating cylinder viscometer
When motor oils are used in European and North American conditions, the oil
viscosity data at -18°C is required in order to assess the ease with which the engine starts. A
specially adapted rotating cylinder viscometer, known in the literature as the ‘Cold Cranking
Simulator’ (CCS), is used for this purpose (ASTM D2602). The schematic diagram of this
viscometer is shown in Figure 2.14.
The inner cylinder is rotated at constant power in the cooled lubricant sample of
volume about 5 [ml]. The viscosity of the oil sample tested is assessed by comparing the
rotational speed of the test oil with the rotational speed of the reference oil under the same
conditions. The measurements provide an indication of the ease with which the engine will
turn at low temperatures and with limited available starting power. In the case of very viscous
fluids, two cylinder arrangements with a small clearance might be impractical because of the
very high viscous resistance; thus a single cylinder is rotated in a fluid and measurements are
calibrated against measurements obtained with reference fluids.
Cone on Plate Viscometer
The cone on plate viscometer consists of a conical surface and a flat plate. Either of these
surfaces can be rotated. The clearance between the cone and the plate is filled with the fluid
and the cone angle ensures a constant shear rate in the clearance space. The advantage of this
viscometer is that a very small sample volume of fluid is required for the test. In some of
these viscometers, the temperature of the fluid sample is controlled during tests. This is
achieved by circulating pre-heated or cooled external fluid through the plate of the
viscometer. These viscometers can be used with both Newtonian and non-Newtonian fluids
as the shear rate is approximately constant across the gap. The schematic diagram of this
viscometer is shown in Figure 2.15.
Aerodynamic bearings, which are sometimes known as active gas bearings, function
depending on the relative motion between the bearing surfaces and usually some type of
spiral grooves to draw the air between the bearing lands. This bearing action is very similar to
hydroplaning on a puddle of water in the case of automobiles moving at high speeds. At a
lower speed, the tyre cuts through the water on the road. In a similar way, aerodynamic
bearings require a relative motion between surfaces, when there is no motion or when the
motion is not fast enough to generate an air film, the bearing surfaces will come into contact.
Aerodynamic bearings are often referred to as foil bearings or self-acting bearings, and they
generate pressure within the gas film by viscous shearing. This type of bearing is relatively
simple because it is independent of an external pressure source and mechanism. However, its
application is limited due to the fact that the surfaces require a very high standard of accuracy
and a low load capacity is also not suitable for applications where frequent starts and stops or
change of direction is required. The aerodynamic bearing system is however simpler and
cheaper to operate compared to the aerostatic system.
AEROSTATIC BEARINGS
Precise axis definition and a high accuracy over a wide speed range
Good performance of the lubricant at extremely low and extremely high temperatures.
The very-high-temperature operations feasible are limited only by the less capabilities
of bearing and journal materials [5]
These bearings mostly find their applications in the field of marine engineering
As they are having high load carrying capacity, they are highly applicable in marine
turbo chargers, marine engine shafts and in similar applications.
These also find their applications in machine tools. In vertical milling machines,
boring machines, drilling machines etc, they are widely applicable
They are also used mainly in case of highly précised machine tools as in case of
spindle of lathe head stock etc.
In gas compressors, vertical turbines, electrical generators, motors and many other
applications involves the use of hydrostatic thrust bearings.
HYDROSTATIC BEARING ANALYSIS
Load Capacity
The total load supported by the bearing can be obtained by integrating the pressure
distribution over the specific bearing area
After eliminating the unnecessary terms the final frictional power is
UNIT 8
BEARING MATERIALS
The bearing industry uses different materials for the production of the various bearing
components. Each and every bearing is carefully designed by choosing appropriate bearing
materials. The selection of bearing material plays very crucial role in designing the bearing.
Since every material has its own significance there should be certain classification of
materials that gives the appropriate choice for selection of bearing materials.
The bearing materials should pocesses certain properties for the full function of
bearing. When the journal and the bearings are having proper lubrication separating the two
surfaces in contact, the only requirement of the bearing material is that they should have
sufficient strength and rigidity. The conditions under which bearings must operate in service
are generally far from ideal, so the other properties must be considered in selecting the best
material. Some of them are listed below.
Compressive strength:
The maximum bearing pressure is considerably greater than the average pressure obtained
by dividing the load to the projected area. Therefore the bearing material should have high
compressive strength to withstand this maximum pressure so as to prevent extrusion or the
other permanent deformation of the bearing.
Fatigue strength:
The bearing material should have sufficient fatigue strength so that it can withstand
repeated loads without developing surface cracks. It is of major importance in aircraft and
automotive engines.
Conformability:
It is the ability of the bearing material to accommodate shaft deflections and bearing
inaccuracies by plastic deformation (or creep) without excessive wear and heating.
Embedability:
It is the ability of bearing material ti accommodate (or embed) small particles of dust ,
grit etc., without scoring the material of the journal.
Bondability:
Many high capacity bearings are made by bonding one or more thin layers of a bearing
material to a high strength steel shell. Thus, the strength of the bond i.e. Bondability is an
important consideration in selecting bearing material.
Corrosive Resistance:
The bearing material should not corrode away under the action of lubricating oil. This
property is of particular importance in internal combustion engines where the same oil is used
to lubricate the cylinder wall s and bearings. In the cylinder, the lubricating oil comes into
contact with hot cylinder walls and may oxidize and collect carbon deposits from the walls.
Thermal conductivity:
The bearing materials should be of high thermal conductivity so as to permit the rapid
removal of the heat generated by friction.
Thermal expansion:
The bearing materials should be of low coefficient of thermal expansion, so that when
the bearing operates over a wide range of temperature, there is no undue change in the
clearance.
Various materials are used in practice, depending on the requirement of the actual
service conditions.
Babbitt metal:
The tin base and lead base babbits are widely used as a bearing material because they
satisfy most requirements for general applications. The babbits are recommended where the
maximum bearing pressure (on projected area) is not over 7 to 14 N/mm² .When applied in
automobiles, the babbit is generally used as thin layer , 0.05 mm to 0.15 mm thick, bonded to
an insert or steel shell. The composition of the metals is as follows:
Tin base babbits: Tin 90%; Copper 4.5%; Antimony 5%; lead0.5%.
Lead base babbits: lead 84%; Tin 6%; Antimony 9.5%; Copper 0.5%.
Bronzes:
The bronzes (alloys of copper, tin and zinc) are generally used in the form of
machined bushes pressed into the shell. The bush may be in one or two pieces. The bronzes
commonly used for bearing material are gun metal and phosphor bronzes.
Gun Metal: (copper 88%; Tin 10%; zinc2%) is used for high grade bearings
subjected to high pressures (not more than 10 N/mm² of projected area ) and high
speeds.
Phosphor Bronze: (copper 80%;Tin 10; Lead 9%; Phosphorus 1%) is used for
bearings subjected to very high pressures (not more than 14 N/mm² of projected area)
and speeds.
Cast iron:
The cast iron bearings are usually used with steel journals. Such type of bearings are
fairly successful where lubrication is adequate and the pressure is limited to 3.5 N/mm² and
speed to 40 meters per minute.
Silver:
The silver and silver lead bearings are mostly used in air craft engines where the
fatigue strength is the most important consideration.
Non-metallic bearings:
The various non-metallic bearings are made of carbon–graphite, rubber, wood and
plastics. The carbon–graphite bearings are self lubricating, dimensionally stable over a wide
range of operating conditions, chemically inert and can operate at higher temperatures than
other bearings. Such types of bearings are used in food processing and other equipment
where contamination by oil or grease must be prohibited. These are also used in applications
where the shaft speed is too low to maintain a hydrodynamic oil film. The soft rubber
bearings are used with water or other low viscosity lubricants, particularly where sand or
other large particles are present. In addition to the high degree of Embedability and
conformability, the rubber bearings are excellent for absorbing shock loads and vibrations.
These are used mainly on marine propeller shafts hydraulic turbines and pumps. The wood
bearings are used in many applications where low cost, cleanliness in attention to lubrication
and anti seizing is important.
Tin bronze
This covers a range of alloys of copper and tin containing between 5% and 12% tin.
The tin content improves strength at the expense of tribological bearing properties such as
conformability and Embedability. At tin contents below 5% there is no significant increase in
strength and wear resistance, and above 12% tin alloys are brittle and difficult to machine.
Phosphor bronze
Small additions of phosphorus in tin bronze, typically 0.4% to l%, improve the
castability of the alloy. The very hard copper phosphide phase is introduced, increasing the
hardness, wear resistance and strength of the alloys, again at the expense of bearing
properties. Hardened mating surfaces are essential. Small additions of lead can be added to
improve bearing properties, but will reduce strength.
Leaded bronze
Copper-lead
These are materials formed by adding lead to unalloyed soft copper or copper with
minor additions. They contain large quantities of lead, typically 20% to 35%, with sometimes
as much as 50%. They have a low load capacity relative to other copper alloys, but excellent
tribological properties. They are often cast onto steel backing to improve load capacity. Such
high contents of lead make these alloys difficult to cast by conventional techniques; very
rapid cooling is required. Small additions of alloying elements such as tin, zinc or nickel are
used to improve castability. These materials are sometimes confusingly also termed lead
bronze. The lead phase is susceptible to corrosion by weak organic acids and can therefore be
overlay plated to advantage with a very thin layer of lead-tin or lead-indium for protection.
Aluminum bronze
Basically, these are alloys of copper with up to 11% of aluminum but frequently
contain other additions such as iron, manganese and silicon to further improve strength,
hardness and impact resistance. The alloys usually contain very hard particles, resulting in
good mechanical properties and wear resistance, at the expense of bearing properties.
Hardened mating surfaces and good lubrication are essential. They have excellent resistance
to corrosion and erosion, especially in marine and similar aggressive environments
Gunmetal
The addition of zinc to tin bronze in quantities up to 6% improves the cast ability of
the alloys which are known as gunmetal’s. Besides improving the cast ability, the zinc
improves the retention of mechanical properties at elevated temperatures but it reduces the
tribological properties. Up to 8% lead can be added to improve bearing properties. A wide
range of gunmetal’s is available with differing additions of tin, zinc and lead suitable for a
variety of end user requirements and manufacturing techniques.
Brass
Brasses are alloys of copper and zinc, typically containing between 20% and 40%
zinc. They are available as cast and in all wrought forms such as plate, sheet, rod, section,
forgings and tube. Without further alloying additions, brass has moderate tribological
properties. Additions of lead give free-machining brasses that are easy to machine and have
potential economic advantages. These are ideal for components with non-critical bearing
applications involving light loadings. Other additions such as manganese, silicon, aluminum
and iron are made to give high-tensile brasses with improved load capacity and tribological
properties.
UNIT 6
FRICTION
DRY FRICTION REGIME
There is no lubrication film between the sealing end faces. The friction is mainly
decided by the solid interaction of the gliding plane. Under the general engineering condition,
the sealing surface may adsorb the gas (or the steam of the medium) or oxide layer. Now two
end faces directly contact, which leads to severe wear and tear. The load and the material of
the friction pairs have obvious influence on the friction process.
BOUNDARY FRICTION
When the friction between the sealing faces happens, On the surfaces, there is a layer
of boundary film of the fluid molecules. This fluid film is very thin and separate two end
faces. This friction is called the boundary friction. In boundary friction regime, the boundary
film has the lubrication function, and the liquid pressure is difficult to be measured [2].
Generally, the boundary film consists of 3-4 layers of the molecules, and its thickness is
about 200 A (1 A= I 0-1° m) [3]. The boundary film is partly discontinuous, and there are
solid contacts in some areas. The micro-convex bodies of the solid surface bear almost all the
load, as shown in Fig.2. The viscosity of the liquid film has no significant effect on the
friction properties. The frictional behavior depends largely on the lubricating properties of the
boundary film and the material of the friction pairs.
According to boundary friction theory Mayer studied the true state of the leak flowing
in the gap of the end faces of mechanical seals when exits no obvious pressure difference and
built up the flowing theory of the fluid exchange [2].The liquid mainly permeates through the
seal faces through the gap. There are many rough discontinuous maze caves along the whole
width of the seal faces, so while the scaling rings revolve, the liquid exchanges in the dinky
gaps and the caves of two contacting friction surfaces is under the residual pressure and the
centrifugal force. The gaps of friction surface seldom connect each other in the boundary
friction regime. The above-mentioned gaps are formed because of the separation of the solid.
When one of two rings revolves, the liquid is transferred from one gap to another, which
causes the leakage, as shown in fig.3.
There is a layer of stable lubricant film between the friction pairs of the end faces of
mechanical seals. This extremely thin lubricant film can separate one end face front the other
so that the sliding surfaces don't directly contact. At this time the friction force is generated
only by the sheer force of the viscous fluid, and it is much less than that in the dry friction
regime. And there is no wear and tear of the solid surfaces. This friction regime is called the
fluid friction. In completely fluid friction regime the dynamic viscosity of the lubricant
affects the frictional property. Now the lubricant fluid shows its volume property. The
friction happens in the interior of the lubricant.
With the wave of the seal end face reduced, the gap of friction pairs becomes smaller.
The highest peak of the surface roughness will contact,. This is called the mixed friction
regime. The end faces of mechanical seals are irregular rough surfaces. The fluid film
between the end faces is extremely thin, and it has the same order of magnitude as the surface
roughness. Therefore, the high-frequency roughness and low-frequency wave of the surface
topography and the radial taper of the overall form error have great influence on the
performance of mechanical seals. The lubricant film of hydrodynamic pressure or hydrostatic
pressure is formed between the end faces, that is, there are several mixed frictions between
the contact surfaces at the same time, such as the fluid friction and the boundary friction, the
boundary friction and the dry friction, the fluid friction and the dry friction, and the boundary
friction and the dry friction.
In mixed friction regime, the fluid film and the contact micro-convex body between
the end faces of mechanical seals bear the total external load caused by the force of the elastic
element and the sealed medium pressure. The total friction forces include two parts, namely,
one generated by the sheer force of the viscous fluid film in the lubricating regime and the
other generated by the cleformation of micro-convex bodies in the contact regime of micro-
convex bodies. The dynamic viscosity and the material of the friction pairs have obvious
influence on the frictional process. Now, there is minor wear, and the friction factor is also
very small.
The friction factor of the end faces is one of the main parameters characterizing the
friction regime. In different friction regime, the friction factor of the friction end faces is not
the same. Mayer presented the friction factors of the different friction regimes [2], which are
listed in Table 1
The duty parameter G was put forward by Stribeck after his research on the bearing
lubricity in 1900-1902. Afterwards,
SommerleId, Gimbel, Hershey .etc applied this similarity number of the friction characteristic
in the field of the sealing technology. The duty parameter could express the friction
characteristic of mechanical seals. Its magnitude indicates the operating condition of
mechanical seals and the carrying power of the liquid film. The duty parameter of mechanical
seals was defined as the ratio of the viscosity force of the liquid film between the end faces to
the locking force of the end faces Pg. Where p is Fluid dynamic viscosity (Pass), v is Average
slide speed of the seal surfaces (m/s), b is Effective seal width of the seal ring (m), n is
Rotational speed (rpm), pg is Locking force of the end faces (Pa), A„ is Area of the seal
surface (m), p,p is Spring pressure (Pa), fi is Balance factor, ps is Medium pressure (Pa) .
Where µ is Fluid dynamic viscosity (Pa-s), v is Average slide speed of the seal
surfaces (m/s), b is Effective seal width of the seal ring (m), n is Rotational speed (rpm), pg is
Locking force of the end faces (Pa), Aa is Area of the seal surface (m), mg is Spring pressure
(Pa), β is Balance factor, Ps is Medium pressure (Pa).
The method that the friction regime is judged by the duty parameter G has been put
forward by Chen [5]. When G.>I x10-6, 2x10-8<G<5x le and 5x10-8<G<1 x10-6, the
frictional pairs work in fluid friction regime. Boundary friction regime and mixed friction,
respectively.
MAYER METHOD
The relationship between the contact pressure coefficient Kg of the end faces and the
clearance height h formed by the roughness of the end faces is shown in Fig.4 Which was
obtained from the experiment by Mayer. The boundary or mixed friction regime of
mechanical seals can be judged from Fig .4.
The friction regime can also be judged by the relative film thickness λ. The relative
film thickness was defined as the ratio of the average thickness of the liquid film 110 between
the end faces to the total surface roughness of the end faces σ.
The relationship among the average thickness of the liquid Min between the end faces of
mechanical seals he, the duty parameter G, the friction factor f and the average radius of the
end faces r,„ can be expressed by Eq.(4) [6].