Wear Behavior Investigations of Journal Bearing of an IC Engine
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[Bhuptani , 2(8): August, 2013] ISSN: 2277-9655 Impact Factor: 1.852 IJESRT INTERNATIONAL JOURNAL OF ENGINEERING SCIENCES & RESEARCH TECHNOLOGY Wear Behavior Investigations of Journal Bearing of an I.C. Engine Small End Connecting Rod for Brass, Gunmetal & Cast Nylon K.M Bhuptani *1 ,DR. J. M. Prajapati 2 *1 PhD Scholar, Department of Mechanical Engineering, J.J.T. University, Jhunjhunu, Rajasthan, India 2 Associate Prof., Department of Mechanical Engineering, M.S.U., Baroda, Gujarat, India [email protected] Abstract In this study the wear behavior of brass, gun metal and Cast Nylon based Bushing bearing in wet conditions at a speed of 900 rpm . The wear test of these bearing was performed in new wear testing machine. The wear test were carried out under different loads like 10N, 20N, 30N and fixed speed of the motor at 900 rpm. The Lubricant used for the test is SAE#) and it is used for all test. The wear characteristics were determined with respect to load, shaft speed and time. The main objective of the study is to evaluate the wear rate of different journal bearings at different loading conditions. The main objective of this experimental study was to checked and compares conventional bearing materials with respect to new bearing material name Cast Nylon. It was found that because of co-efficient of friction, the power loss due to friction was five times in Brass and 2.5 Times in Gun Metal compare to Cast Nylon, comparing at the same speed, load and lubricant. Even density of the Brass and Gun Metal is approximately seven times heavier than the Cast Nylon. Therefore, we can replace conventional bearing made either from the Brass or Gunmetal by the new material name Cast Nylon and improve the performance of the engine bearing by way of reducing power loss and less induced temperature due to lower value of co-efficient of friction. Keywords : Wear rate, Journal bearings, co-efficient of friction, power loss, engine performance, Weight loss. Introduction Friction and wear always occur at machine parts and this relative movement is in one direction or a which run together. This affects the efficiency of successive movement under the effect of the load so that machines negatively. Today, many industrial the pressure on the adjacent projections is big enough to applications use vacuum conditions. Therefore, it became make a load plastic deformation and adhesion. This essential to determine the tribological behavior of the adhesion will be at a high grade of efficiency and machine components running under these conditions. In capability in relative to the clean surfaces, and adhesion this paper, friction and wear behavior of BRONZE and will take place between a number of these projections BRASS alloy which is used commonly in the industry as whose sizes will be bigger and the area will be increased a bearing material. Nowadays, especially with the growth during movement [2]. of the plastics industry and the development of high- Wear resistance is one of the most important strength fibers, vast range combinations of materials are properties that journal bearings should possess. Several available for use in engineering fields. To take the studies and investigations have been made in order to advantages of new material developed, in this paper improve the wear resistance. The researchers investigate attempt is made to offer Cast Nylon 6 as the non metallic friction and wear behavior of materials because of the material in place of conventional material. adverse effect observed in the performance and life of Journal bearing materials are expected to have machinery components. Much of the research reported in several properties such as low friction coefficient, high the literature was carried out under the atmospheric load capacity, high heat conductivity, compatibility, high conditions. However, some tribological behaviors have wear and corrosion resistance. These properties directly been recently investigated under the vacuum conditions. affect the fatigue and wear life of the bearing [1].There Especially, as a result of some new developments in are several theories which were found to explain the aeronautic, space, electronic, material, metallurgy, phenomenon of adhesion wear, and from that the simple chemistry, coating and manufacturing industrial areas adhesion wear theory. The adhesive wear occurs when necessitate the machinery components to be investigated two surfaces are moving relatively one over the other, under the different conditions. Therefore there is great http: // www.ijesrt.com (C) International Journal of Engineering Sciences & Research Technology [2177-2186] [Bhuptani , 2(8): August, 2013] ISSN: 2277-9655 Impact Factor: 1.852 interest among the researcher to estimate to the effect of adhesion wear is affected by pressure and velocity the loads and speeds on the material’s friction and wear concerning load and movement. This p.v. value (load behavior. capacity) is important for wear analysis. If bearings are In the recent years studying the metallurgy used appropriately on p.v. values, wear quantity can be science gave to humanity an ever growing range of decreased [9]. useful alloys. Whilst many of these alloys are put to There are non – metallic materials that do not purposes of destruction, we must not forget that others exist in nature, although they are manufactured from have contributed to the material progress of mankind and natural substances such as oil, coal and clay. They to his domestic comfort. This understanding of the combine good corrosion resistance with ease of materials resources and nature enable the engineers to manufacture by molding to shape and relatively low cost. select the most appropriate materials and to use them Synthetic adhesives are also being used for the joining of with greatest efficiency in minimum quantities whilst metallic. Journal bearing materials are expected to have causing minimum pollution in their extraction, several properties such as low friction coefficient, high refinement and manufacture. In the past few years, wood, load capacity, high heat conductivity, compatibility, high iron and skin have been used as journal bearing wear and corrosion resistance. These properties directly materials. Later, brass, bronze and white metal have also affect the fatigue and wear life [10,11–12]. Wear and found some applications. Currently, in addition to these wear mechanisms depend on a lot of factors at journal bearing materials, aluminum and zinc based materials are bearings. These factors and their effects can be examined used as journal bearing materials. With technological in a tribological system. These factor include base improvements, self-lubricated sintered bearings and friction element, opposite friction element, interim plastic materials are used where continuous lubricating is matter, ecology, loading and movement [13]. Of these impossible. Therefore, it is essential that the bearing wear mechanisms, adhesion wear is affected by pressure material be chosen depending upon area of application. and velocity concerning load and movement. This p.v. Wear resistance is one of the most important properties value (load capacity) is important for wear analysis. If that journal bearings should possess. Copper based bearings are used appropriately on p.v. values, wear materials are widely used as bearing materials because quantity can be decreased [14].Natural cast nylon has the they have high thermal and electrical conductivity, self- ability to operate effectively without the need for lubrication property, good corrosion and wear resistance lubricants and has an increased resistance to wear of over [3].The effect of tin on wear in copper based materials is 5 times that for plain bearings manufactured from non- important. Copper based tin bronzes are used as bearing ferrous metals. As is the case with virtually all nylons it materials to have a high wear resistance [4]. Friction and is easy to machine, pleasant to work with and relatively wear properties of these materials can be improved by light weight - one eighth that of brass - making the adding tin [5] Tin bronze (90% Cu and 10% Sn) is the handling and fitting of large components manufactured most suitable bearing material under corrosive in cast nylon a relatively easy matter.[15] conditions, at high temperatures and high loads. Lead and tin based white metal alloys are used Wear Theories due to their antifriction property as bearing materials. The adhesive wear occurs when two surfaces These alloys are produced by casting and spray are moving relatively one over the other, and this relative deposition method. These casting alloys contain inter movement is in one direction or a successive movement metallic phase. The process variables during spray under the effect of the load so that the pressure on the forming of Babbitt bearing metal alloy strongly influence adjacent projections is big enough to make a load plastic the microstructure and porosity of the spray deposits. deformation and adhesion. This adhesion mechanism is The wear rate of the spray-formed alloy is lower than shown in the FIGURE 1 and will be at a high grade of that of the as-cast alloy. Wear properties of the spray- efficiency and capability in relative to the clean surfaces, formed alloy are attributed to the decreased inter metallic and adhesion will take place between a number of these phases and modification in the microstructure of the projections whose sizes will be bigger and the area will eutectic phases [6]. SnPbCuSb (white metal) alloys