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Department of Mechanical Engineering, Korea Advanced Institute of Science and Technology, ME3221, Guseong-dong, Yuseong-gu,
Daejeon 305-701, Republic of Korea
Available online 15 June 2004
Abstract
Journal bearing materials are required to have special characteristics such as compatibility with rubbing interface materials,
embeddability for particles and wear debris, conformability to accommodate misalignment, thermal and corrosion resistance. Although white metals or babbitt metals used in most journal bearing have almost the required characteristics, they have possibility of
seizure between the bearing material and the journal when the oil lm is broken.
In this study, a hybrid composite journal bearing composed of carbon ber reinforced phenolic composite liner and metal
backing was manufactured to solve the seizure problem of metallic journal bearing materials because the carbon ber has selflubricating ability and the phenolic resin has thermal resistance characteristics. To estimate the wear resistance of carbon ber
phenolic composite, wear tests were performed at several pressures and velocities. The oil absorption characteristics, coecient of
thermal expansion, strength and stiness of the composite were also tested. Using the measured stiness values, the thermal residual
stresses in the composite were calculated to check the reliability of the composite journal bearing.
2004 Elsevier Ltd. All rights reserved.
Keywords: Carbon ber reinforced phenolic; Hybrid composite journal bearing; Wear volume; Friction coecient; Axiomatic design; Co-cure
bonding
1. Introduction
The major problem of white metal journal bearing
used in large marine vessels is the seiziure between the
journal and bearing when the lubricant lm is broken
under heavy load, or low velocity applications, or start
and stop periods.
To solve the seizure problem, polymers are widely
used in the parts of bearings, gears, and oil sealings
because the friction coecient of polymers is much low
compared to that of metallic materials due to their selflubrication properties [1].
However, the low mechanical strength, low thermal
conductivity and large thermal expansion of polymers
limit the wide applications of polymer bearings. In order
to overcome these inferior properties of neat polymers,
*
Corresponding author. Tel.: +82-42-869-3221; fax: +82-42-8695221.
E-mail addresses: dglee@kaist.ac.kr, passion002@kaist.ac.kr (D.G.
Lee).
0263-8223/$ - see front matter 2004 Elsevier Ltd. All rights reserved.
doi:10.1016/j.compstruct.2004.04.057
360
T (C)
155
105
80
40
355
time (min)
1: Hoop
2: Radial
3: Axial
2
6
6
Table 1
Coecients of thermal expansion (CTE) of composite materials
Asbestos phenolic
Carbon phenolic
Hoop
Radial
Axial
7.19
1.23
27.63
40.7
22.01
1.84
Table 6
Shear strength and modulus of the composite materials
1: Hoop
2: Radial
3: Axial
45
1
361
Materials
13
directions
23
directions
Shear strength
(MPa)
Asbestos phenolic
Carbon phenolic
34.5
75.0
17.2
17.5
Shear modulus
(GPa)
Asbestos phenolic
Carbon phenolic
12.5
(a)
(b)
2.5
5.77
1.4
3.75
Table 2
Swelling (%) of composite materials
Asbestos phenolic
Carbon phenolic
Hoop
Radial
Axial
0.03
0.01
0.11
0.09
0.12
0.02
Table 3
Compressive strength (MPa) of the composite materials
Asbestos phenolic
Carbon phenolic
1 (hoop)
2 (radial)
3 (axial)
86.2
220
105.3
490
75.3
220
Table 4
Tensile strength and elastic modulus of the composite materials
Materials
1 (hoop)
Elastic
modulus
(GPa)
Asbestos
phenolic
Carbon
phenolic
13.3
2 (radial)
3.0
3 (axial)
3.5
73.2
14.3
50.7
Tensile
strength
(MPa)
Asbestos
phenolic
Carbon
phenolic
82.0
11.1
15.6
130
30.0
130
Table 5
Poissons ratio of the composite materials
Asbestos phenolic
Carbon phenolic
t12
t13
t23
0.496
0.2
0.442
0.07
0.401
0.06
La Lb
100
Lb
Sliding direction
6
5
362
Strain gauge
Photo-type
sensor
Disk
Counter
weight
Pneumatic
cylinder
Weight
Frequency
converter
Motor
400
300
200
100
0
0
50
100
150
Time (min)
Fig. 6. Wear volume of the carbon phenolic and asbestos phenolic
composites with respect to sliding time at the same PV value. N:
Asbestos phenolic (P: 1.2 MPa, V: 1.7 m/s), r: Asbestos phenolic (P:
1.6 MPa, V: 1.25 m/s), }: Carbon phenolic (P: 1.2 MPa, V: 1.7 m/s),
j: Carbon phenolic (P: 1.6 MPa, V: 1.25 m/s).
two materials were observed. The wear volume of carbon ber reinforced phenolic composites was little
changed with respect to load and velocity, but the wear
volume of asbestos ber reinforced phenolic composites
increased much with respect to load and velocity. Also
the wear volume of asbestos ber reinforced phenolic
composites was more dependent on the pressure than
the speed at constant PV value. When the pressure increased and speed decreased, the wear volume increased
as shown in Fig. 6 and wear surface of this condition
was rougher than that of another condition as shown in
Fig. 7(a) and (b). This implies that the large void of
asbestos ber reinforced phenolic composites directly
inuenced the wear behavior of the composite greatly.
If the stress due to the friction force exceeded the
shear strength of the specimen, a crack initiated and
propagated along the void of the specimen, which
plucked o the specimen as shown in Fig. 7(a), consequently large wear volume occurred.
For the carbon ber reinforcement phenolic composites, the wear volumes were less than those of the
asbestos reinforced phenolic composites under the same
values of PV because of the self lubricating capability
and high conductivity of carbon ber and the ber
fracture and material in the adherent membrane were
observed as shown in Fig. 7(b). When the two sliding
surfaces come into contact, asperities of the softer surface were easily deformed and some were fractured by
the repeated loading action. These repeated loading
action caused crack nucleation under the very near
surface and further loading and deformation caused
cracks to extend and propagate, joining neighboring
ones. The cracks propagated along the week part, i.e.,
interface between ber and matrix, the ber fracture
occurred by repeated loading.
The friction coecients of two materials were obtained under the constant normal force of 40 N and the
speed of 1.25 m/s by dividing friction force by the
vertical force as shown in Fig. 8. The dry mean friction
coecients of the asbestos ber reinforced phenolic
and the carbon ber reinforced phenolic composite
were 0.27 and 0.16, respectively. The reason for the low
friction coecients of the carbon phenolic composite is
the lubricating action of carbon bers. The friction
coecients of carbon phenolic composite in the initial
transient state were higher than that in the steady state
because the material adherent in the membrane reduced the friction in the steady state [11]. In case of
asbestos ber reinforced phenolic composite, the
material adherent in the membrane of steel counterface
was discontinuous and nonuniform as shown in Fig.
7(a). Because of poor adhesion of material adherent in
the membrane to the substrate, the membrane was
peeled o during sliding so that a roll-like wear debris
was produced. The high wear volume and friction
coecient of the asbestos ber reinforced phenolic
composite was attributed to its poor ability to form a
continuous material adherent in the membrane thereby
providing inadequate protection when the soft polymer
was damaged by rough asperities on the harder counterface.
The carbon ber reinforced phenolic composite
specimens were also tested with respect to the oil
absorption amount into the composite to simulate the
actual operating condition for journal bearing. The oil
absorption ratio (%) of the specimens immersed in SAE
30 oil for 13 weeks was listed in Table 7. Fig. 9 shows
the test results in which the wear volume in the wet
friction was smaller than that in the dry friction due to
the oil lm layer on the metal disc. The oil absorbed into
the specimen drained as the volume of loaded specimen
was worn-out, which formed the oil lm layer. The
specimens immersed in the oil longer than 2 weeks had
363
Fig. 7. Wear surface of the two composite materials. (a) Asbestos phenolic (P: 1.2 MPa, V: 1.7 m/s), (b) Asbestos phenolic (P: 1.6 MPa, V: 1.25 m/s),
(c) Carbon phenolic (P: 1.2 MPa, V: 1.7 m/s), (d) Carbon phenolic (P: 1.6 MPa, V: 1.25 m/s).
18
P: 1.2MPa, V: 1.7m/s
P: 30N V:1.7m/s
60
12
15
9
Carbon phenolic composite
6
40
oilless
0.4%
0.90%
1%
20
0
0
2000
4000
6000
8000
Time (sec)
30
60
90
120
150
2 weeks
3 weeks
0.4
0.9
1.0
364
40
900
R385.6
Shaft diameter : 770
145
340
Bagging film
Breather
Sealant
Steel backing
Prepreg
Release film
Bagging film
(a)
Key groove
Steel backing
Composite lining
(b)
365
Fig. 13. Stress distribution in the hoop direction of hybrid composite journal bearing.
5. Conclusion
References
Acknowledgements
This work has been supported in part by National
Research Laboratory Project of Ministry of Science and
Technology in part by BK 21. Their supports are
gratefully acknowledged.
366
[10] ASTM Standard (D 5515-97). Standard test methods for determination of the swelling properties of bituminous coal using
a dilatometer. American Society for Testing and Materials;
1997.