Development of new low friction thrust ball bearing with optimize geometry

Abdul Khalid, Alif Iqmal (2024) Development of new low friction thrust ball bearing with optimize geometry. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Bearings serve a variety of functions and are among the most common types of components found in mechanical and civil engineering structures. Because of its versatility and capacity to withstand axial loads while permitting rotation, thrust ball bearings find extensive use in mechanical systems. Traditional thrust ball bearings suffer from excessive energy consumption and poor efficiency due to large frictional losses. In response, a fresh strategy is developed to improve the thrust ball bearing's design. Improving the geometry of thrust ball bearings in order to decrease friction is the primary goal of this work. Using Catia V5 software for design and SLS 3D printing technology for prototype creation, the study the bearing's structural properties and detect any prospective weak places. To find and discover any potential weak places, the bearing is simulated using Simsolid software. The outcome for Simsolid was evaluated in comparison to the prior project's roller bearing results in order to guarantee improved performance. Modifying the contact angle, groove form, and ball diameter are all potential ways to lessen the frictional losses. The results demonstrate that the prior project's low measurement values indicate that roller bearings, not thrust ball bearings, provide superior simulation results. This is because, instead of using thrust ball bearings, the rollers used in the action have a broad contacting surface. Through the use of vibration analysis experiments, the prototype's efficacy and performance were assessed. Using vibration testing and a scanning electron microscope (SEM), a series of tests will be conducted to evaluate the friction, load capacity, and durability of the proposed low friction thrust ball bearing. To define their parameters, the new bearing design's prospective benefits are contrasted with those of the prior project, which included roller bearings. The majority of the enhanced prototypes outperformed the baseline versions, according to the study's overall results. A key component influencing the rotational force acting on the contact surface of the bearing was identified. Importantly, when subjected to greater stresses, prototypes created utilising selective laser sintered (SLS) technology underwent plastic deformation and merged with steel, resulting in a smoother surface. The material used in the previous project made the vibration testing go more smoothly than with the thrust ball bearing. While the roller bearings were entirely made of Nylon P12, the ball bearings in this project were steel with some Nylon PA12 added. The procedure significantly increased the lifetime and durability of the bearings employed. The result was a less noticeable amount of vibration from the machine because of the improved surface. Photos taken with a scanning electron microscope (SEM) provide credence to the study and show that squares are the best form for any kind of research. Furthermore, it was observed that thrust ball bearings outperformed the previously used roller bearings in terms of performance and longevity, despite the fact that their Nylon PA12 substance made their surfaces less smooth. The optimised design of the bearing shows its promise in many future applications.

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