Operating limits for acoustic measurement of rolling bearing oil film thickness

An ultrasonic pulse striking a thin layer of liquid trapped between solid bodies will be partially reflected. The proportion reflected is a function of the layer stiffness, which in turn depends on the film thickness and its bulk modulus. In this work, measurements of reflection have been used to determine the thickness of oil films in elastohydrodynamic lubricated (EHL) contacts. A very thin liquid layer behaves like a spring when struck by an ultrasonic pulse. A simple quasi-static spring model can be used to determine the proportion of the ultrasonic waves reflected. Experiments have been performed on a model EHL contact between a ball and a flat surface. A transducer is mounted above the contact such that the ultrasonic wave is focused onto the oil film. The reflected signals are captured and passed to a PC for processing. Fourier analysis gives the reflection spectrum that is then used to determine the stiffness of the liquid layer and hence its thickness. In further testing, an ultrasonic transducer has been mounted in the housing of a deep-groove ball bearing to measure the film generated at the outer raceway as each ball passes. Results from both the ball-flat and ball bearing measurements agree well with steady-state theoretical EHL predictions. The limits of the measuring technique, in terms of the measurable rolling bearing size and operating parameters, have been investigated

Integrating Dynamics and Wear Modelling to Predict Railway Wheel Profile Evolution

The aim of the work described was to predict wheel profile evolution by integrating multi-body dynamics simulations of a wheelset with a wear model. The wear modelling approach is based on a wear index commonly used in rail wear predictions. This assumes wear is proportional to Tγ, where T is tractive force and γ is slip at the wheel/rail interface. Twin disc testing of rail and wheel materials was carried out to generate wear coefficients for use in the model. The modelling code is interfaced with ADAMS/Rail, which produces multi-body dynamics simulations of a railway wheelset and contact conditions at the wheel/rail interface. Simplified theory of rolling contact is used to discretise the contact patches produced by ADAMS/Rail and calculate traction and slip within each. The wear model combines the simplified theory of rolling contact, ADAMS/Rail output and the wear coefficients to predict the wear and hence the change of wheel profile for given track layouts

Acoustic measurement of lubricant-film thickness distribution in ball bearings

An oil-film thickness monitoring system capable of providing an early warning of lubrication failure in rolling element bearings has been developed. The system is used to measure the lubricant-film thickness in a conventional deep groove ball bearing (shaft diameter 80 mm, ball diameter 12.7 mm). The measurement system comprises a 50 MHz broadband ultrasonic focused transducer mounted on the static outer raceway of the bearing. Typically the lubricant-films in rolling element bearings are between 0.1-1.0 μm in thickness and so are significantly smaller than the ultrasonic wavelength. A quasistatic spring model is used to calculate oil-film thickness from the measured reflection coefficient data. An accurate triggering system has been developed to enable multiple reflection coefficient measurements to be made as the contact ellipse sweeps over the measurement location. Experiments are described in which the loading conditions and rotational speed are varied. Lubricant-film thickness distributions measured ultrasonically are described and are shown to agree well with the predictions from classical elastohydrodynamic (EHD) lubrication theory, particularly at high radial loads and low rotary speeds. A range of parameters affecting the performance of the measurement are discussed and the limits of operation of the measurement technique defined. © 2006 Acoustical Society of America

Monitoring of lubricant film failure in a ball bearing using ultrasound

A lubricant-film monitoring system for a conventional deep groove ball bearing (type 6016, shaft diameter 80 mm, ball diameter 12.7 mm) is described. A high-firequency (50 MHz) ultrasonic transducer is mounted on the static outer raceway of the bearing. The transducer is focused on the ball-raceway interface and used to measure the reflection coefficient of the lubricant in the "contact" ellipse between bearing components. The reflection coefficient characterizes the lubricant film and can be used to calculate its thickness. An accurate triggering system enables multiple reflection measurements to be made as each lubricated contact moves past the measurement location. Experiments are described in which bearings were deliberately caused to fail by the addition of acetone, water and sand to the lubricant. The ultrasonic reflection coefficient was monitored as a function of time as the failure occurred. Also monitored were the more standard parameters, temperature and vibration. The results indicate that the ultrasonic measurements are able to detect the failures before seizure. It is also observed that, when us,ed in parallel, these monitoring techniques offer the potential to diagnose the failure mechanism and hence improve predictions of remaining life

Wind turbine main-bearing lubrication - part 1 : an introductory review of elastohydrodynamic lubrication theory

This paper is the first in a two-part study on lubrication in wind turbine main-bearings. Elastohydrodynamic lubrication is a complex field, the formulas and results from which should not be applied blindly, but with proper awareness and consideration of their context, validity and limitations in any given case. The current paper, “Part 1”, therefore presents an introductory review of elastohydrodynamic lubrication theory in order to provide this necessary background and context in an accessible form, promoting cross-disciplinary understanding. Fundamental concepts, derivations and formulas are presented, followed by the more advanced topics of: starvation, dynamic effects, surface roughness interactions and grease lubrication. “Part 2” applies the presented material in order to analyse wind turbine main-bearing lubrication in the context of available film thickness formulas and related results from lubrication theory. Aside from the main-bearing, the material presented here is also applicable to other lubricated non-conformal contacts in wind turbines, including pitch and yaw bearings and gear-teeth

A Railway Wheel Wear Prediction Tool based on a Multibody Software

The wheel wear prediction is a key-topic in the field of railway research as it has big impact on economical and safety aspects of trainset design, operation and maintenance. The aim of this work was to implement a flexible and pre-dictive railway wheel wear tool that, starting from a specific vehicle mission, provides the wheel profile evolution as a function of the distance run. The we-ar estimation tool consists of the use of a sequence of pre and post-processing packages, in which the methodologies now presented are implemented, inter-faced with a commercial multibody software that is used to study the railway dynamics. The computational tool is applied here to several simulation sce-narios. The purpose is to demonstrate its capabilities on wear prediction by evaluating the influence of trainset design and of track layout on the wheel wear growth. Special attention is also given to study how the wear evolution is affected by the friction conditions between the wheel and rail

IJTC2010-41101 Experiments on Grease Performance in Aircraft Landing Gear Pin Joints

ABSTRACT A pin joint simulation machine has been built to test a real landing gear pin joint under realistic loading and reciprocation conditions. The pin is loaded hydraulically using a hydraulic actuator to apply a fixed displacement cycle whilst measuring the reactive torque. The machine was used to measure the torque cycle (and hence friction coefficient) required to operate the joint. In this work a method of evaluating different formulation greases has been proven. This involved measuring their frictional torque and also evaluating performance using a Sommerfeld type approach that displays the different lubrication regimes in the joint for different conditions. Measured friction coefficients were in the region of 0.02 to 0.12 depending on the joint load and articulating speed. In actual gear the surface sliding speed is low and so the joint operates in the boundary regime. The required torque and coefficient of friction have been related to the lubrication mechanisms occurring as a function of articulation angle, reciprocal frequency and applied axial load for lubrication starvation in a reciprocating journal bearing. INTRODUCTION This study focuses on the design of pin joints in aircraft landing gear. The articulation in landing gear systems is achieved by the use of a system of pin joints and members

Ultrasonic oil-film thickness measurement: An angular spectrum approach to assess performance limits

The performance of ultrasonic oil-film thickness measurement in a ball bearing is quantified. A range of different viscosity oils (Shell T68, VG15, and VG5) are used to explore the lowest reflection coefficient and hence the thinnest oil-film thickness that the system can measure. The results show a minimum reflection coefficient of 0.07 for both oil VG15 and VG5 and 0.09 for oil T68 at 50 MHz. This corresponds to an oil-film thickness of 0.4 μm for T68 oil. An angular spectrum (or Fourier decomposition) approach is used to analyze the performance of this configuration. This models the interaction of component plane waves with the measurement system and quantifies the effect of the key parameters (transducer aperture, focal length, and center frequency). The simulation shows that for a focused transducer the reflection coefficient tends to a limiting value at small oil-film thickness. For the transducer used in this paper it is shown that the limiting reflection coefficient is 0.05 and the oil-film measurement errors increase as the reflection coefficient approaches this value. The implications for improved measurement systems are then discussed

Observations on acoustic emissions from a line contact compressed into the plastic region

Some observations from acoustic emissions recorded during a yield test of a bearing raceway compressed into plasticity using a rolling element are presented. The general objective of the study is to establish whether there is enough evidence of the onset of sub-surface plasticity in the acoustic emissions signature. It is discussed here how acoustic emissions monitoring during compression could indicate the onset of subsurface plasticity as a precursor to damage propagation to the surface. Some comparisons are drawn between the acoustic emissions activity levels and time-frequency response during elastic deformation and at yield loads