Develop a new model of low friction of hybrid bearing with precission geometry for light weight industrial application

Mohamad Zaki, Muhammad Iman Haqiemi (2025) Develop a new model of low friction of hybrid bearing with precission geometry for light weight industrial application. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Bearing systems play a crucial role in a wide range of engineering applications, enabling and supporting motion while ensuring the efficient transfer of forces. Among these, thrust ball and roller bearings are widely recognized for their ability to accommodate axial loads during rotation. However, conventional designs of these bearings often suffer from inefficiencies due to frictional forces, resulting in increased energy consumption and wear over time. Addressing this challenge requires innovative approaches that not only reduce friction but also improve the overall structural stiffness and performance of the bearings. This study proposes the development of a novel self-organizing hybrid bearing structure designed specifically for lightweight applications. The focus is on optimizing the geometry of the bearing to minimize friction and enhance mechanical stability. Using Computer-Aided Design (CAD) software, specifically CATIA V5, advanced bearing designs were created with special attention to critical parameters such as contact angle, groove geometry, and ball diameter. These design modifications aim to significantly reduce energy dissipation and improve the operational efficiency of the bearings. The bearing prototypes were fabricated using Selective Laser Sintering (SLS), a rapid prototyping method that enables precise construction of complex designs. The performance of the proposed designs was evaluated through detailed simulations in SIMSOLID, which analyzed key factors such as contact forces, load distribution, and structural stability. The Rectangle geometry stood out as the best performer, offering balanced load distribution and reliable structural stability. While the Square and Circle designs excelled in specific areas, their overall performance was less consistent. The Solid and Triangle geometries were less efficient due to higher forces and moments. Fabrication challenges, such as uneven sintering and porosity from recycled PA12 powder, required design adjustments to address material and 3D printing limitations. Despite these hurdles, the optimized designs significantly reduced energy loss and improved stability, making them ideal for lightweight, energy-efficient applications. This study highlights how geometry optimization and advanced fabrication techniques can enhance bearing performance while promoting sustainability with recycled materials.

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