EMat 2

Catch-up Plan Module

Chapter 5: Bearings Destructive Tests Fabrication Techniques

After working on this chapter, the reader shall be able to:

• explain characteristics of the different types of bearings;

• discuss the different material-testing methods; and
• differentiate the common metal fabrication techniques.

Bearings

Bearings are mechanical assemblies that consist of rolling elements and usually inner and outer races
which are used for rotating or linear shaft applications that reduces friction between moving parts.
There are several types of bearings, such as ball bearings, plain bearings and roller bearings.

1. Ball Bearings

Ball Bearings are mechanical assemblies that contain rolling round elements that are captured
between circular inner and outer races. The purpose of a ball bearing is to reduce rotational friction
and support radial and axial loads. Ball bearings are used primarily in machinery that has shafts
requiring support for low friction rotation. As one of the bearing races rotates, it causes the balls
to rotate as well. Because the balls are rolling they have a much lower coefficient of friction than if
two flat surfaces were rotating on each other. Compared to other rolling-element bearings, the ball
bearing is the least expensive, primarily because of the low cost of producing the balls used in the
bearing .

Types of Ball Bearings

1. Single-row ball bearing- This type of bearing is used in all the fields of mechanical engineering in
general (flaps, bearings of jet engines, transmissions of helicopters, on-board equipment...)
2. Double-row ball bearing- This type of bearing is used in pumps, reducers (wheel and screw), etc.
3. Double-row self-aligning ball bearing-: I t is particularly suitable for applications where considerable shaft
deflections or misalignment are to be expected.

2. Plain Bearings

The plain bearing is an element frequently used in centrifugal pump construction that allows sliding
or rotational motion between two parts of a machine. Their main purpose is preventing wear of the
points of support of the machine, which would take place if the shafts were to roll directly on the structure .

Plain bearings are composed of two parts:

a.Fixed part or support- this part carries the load

b. Bush- the part that gets worn because it is in contact with the moving element.

Types of Plain Bearings

According to Type of contact:

a. Plain or friction bearings
b. Rolling bearings
According to type of lubrication:
a. Self-lubricating bearings:
b. Regularly lubricated bearings:
c. Continuously lubricated bearings

According to position of the rolling bearing:

a. Axial
b. Radial
c. Thrust

Roller Bearings

Roller bearing or Rolling-element bearings are used to carry a load while minimizing friction. Unlike
ball bearings, roller bearings use cylindrical or tapered rolling elements to maintain separation
between moving parts of the bearings. Roller bearings are used primarily in machinery with rotating
shafts that require the support of heavier loads than ball bearings provide. Tapered roller bearings
are often used to accommodate higher thrust loads in addition to the radial loads.

Types of Roller Bearings

a. Cylindrical roller bearings- these bearings can carry heavy radial loads and are able to be used in high-speed
applications.
b. Spherical roller bearings- these bearings can handle axial loading in either direction as well as heavy shock loads.
They are used when dealing with misalignment and shaft deflection.
c. Needle roller bearings- Needle roller bearings are ideal for dealing with radial
space constraints in heavy-load, high-speed applications.
d. Taper roller bearings- These bearings can support radial and thrust loads and
they can only handle unidirectional axial loads

Material-Testing Methods

Materials such as steels generally have to endure an extensive variety of loads such as tension, compression,
bending, etc. When dimensioning materials, the engineers must be able to refer to definite values that describe the
diverse stress limits of the materials used with respect to their temporal course. The stress limit can be based on
either an unacceptable deformation or a breakage. For this purpose, different material-testing methods were
developed to determine the conforming failure limits depending on the type of load and its time course.
Generally, material-testing methods can be divided into two categories:
a. destructive testing
b. non-destructive testing

Destructive Testing

Materials and its components can no longer be used or are damaged when destructive testing is
employed. These procedures are carried out to test material’s failure. It gives information not only
the proper material but also geometry of the component depending on the applied load.
The following are the examples of destructive method:
• tensile test
• compression test
• hardness test
• flexural test
• Charpy impact test
• fatigue test
• creep rupture test
• relaxation test
• cupping test
Non-Destructive Testing (NDT)
Non-destructive testing (NDT) is a testing that uses various combination techniques to assess the integrity,
properties, components, structures and systems of materials without causing damage to them .

The following are the examples of destructive method:

• ultrasonic testing (UT)
• dye penetrant inspection (DPI)
• magnetic particle testing (MPI)
• eddy current testing (ECT)

Metal Fabrication

Metal fabrication is the process of creating metal structures such as machines, parts and structures
from different raw materials. This process includes welding, casting, forging, etc.

Welding

Welding is a process whereby two or more parts are joined together through a combination of heat
and pressure. It is usually used on metals and thermoplastics but can also be used on wood. Four of the popular
types of welding procedures are Stick or Arc Welding, MIG Welding, TIG Welding, and Flux Cored Arc Welding.

Casting

Casting is a process in which materials in a molten state are poured into a mold where they solidify.
The process is used for the mass-production of parts with the reuse of the same mold to create same
products. The casting process can be utilized to produce a large variety of parts that are used in
different industries, ranging from a small plastic toy to a large gas turbine blade.

The following are the major casting processes used in the manufacturing industry:
• Sand casting
• Die Casting
• Centrifugal Casting
• Investment Casting

Forging

Forging is most commonly performed with the use of forging presses or hammering tools that are
powered by electricity, hydraulics or compressed air. Forging results in metallurgical recrystallization and grain
refinement as a result of the thermal cycle and deformation process.
Forging process can be done through hot forging and cold forging.

Quick Assessment:

1. Which of the following are functions of bearings?

a) Ensure free rotation of shaft with minimum friction
b) Holding shaft in a correct position
c) Transmit the force of the shaft to the frame
d) All of the listed answers

2. These bearings have mechanical assemblies that contain rolling round elements that are captured between
circular inner and outer races.
a) Ball bearings
b) Plain bearings
c) Roller bearings
d) Flat bearings
3. This type of bearing is usually used in pumps and reducers.
a) Double-row self-aligning ball bearing
b) Single-row ball bearing
c) Double- row ball bearing
d) Plain bearing

4. This bearing is an element frequently used in centrifugal pump construction that allows sliding or rotational
motion between two parts of a machine.
a) Ball bearings
b)Plain bearings
c) Roller bearings
d) Flat bearings

5. These bearings can carry heavy radial loads and are able to be used in high-speed applications.
a) Cylindrical roller bearings
b) Needle roller bearings
c) Taper roller bearings
d) Spherical roller bearings

6. These bearings can support radial and thrust loads and they can only handle unidirectional axial loads
a) Cylindrical roller bearings
b) Needle roller bearings
c) Taper roller bearings
d) Spherical roller bearings

7. This is a material- testing method wherein materials and its components can no longer be used or are damaged
when destructive testing is employed.
a) Destructive Testing
b) Non-Destructive Testing
c) Combination Testing
d) None of the answers

8. Ultrasonic testing (UT) is an example of ______.

a) Destructive Testing
b) Non-Destructive Testing
c) Combination Testing
d) None of the answers

9. This is a process in which materials in a molten state are poured into a mold where they solidify.
a) Forging
b) Welding
c) Casting
d) Hot Forging

10. This is a process whereby two or more parts are joined together through a combination of heat and pressure.
a) Forging
b) Welding
c) Casting
d) Cold Forging

Engr. Jose Ramil F. Cañas, Ph.D.-TM