Machine Design: Lifetime performance and reliability, Tribologie, System design

© Ontwerpen op levensduurprestatie en betrouwbaarheid

Advanced engineering design Lifetime performance and reliability Dit boek bevat 552 pagina's in full color en meer dan 250 illustraties, 300 formules, 100 case studies en ontwerp voorbeelden, 50 easy calculators en 50 foto's van gefaalde machine onderdelen.
Over het boek Inhoud Index Hoe aan te schaffen?
Inhoud Editie 2012

Over het boek:

In het eerste deel van het boek wordt de basis gelegd voor "Ontwerpen op levensduurprestatie en betrouwbaarheid", inclusief ontwerp procedures om de machine betrouwbaarheid te bepalen en te verbeteren, waarschijnlijkheidsbenadering, faalanalyse, vermoeiingssterkte, statische en dynamische belastbaarheid van geconcentreerde contacten, wrijvingsverschijnselen, slijtage mechanismen, smeermiddel en materiaal selectie. Bovenstaande onderwerpen worden toegepast op ontwerpberekeningen aan diverse dynamisch belaste onderdelen in machines.

Het tweede deel betreft "Ontwerpen van hoge precisie en hoge betrouwbaarheid systemen". De belangrijkste componenten in dergelijke systemen zijn de actuator met controller, de lagers / lineair geleidingen en het frame. De ontwerper wordt inzicht gegeven in de prestaties van deelsystemen in relatie met de systeem specificatie, inclusief het ontwerpen van hydrodynamische lagers en geleidingen, dynamische afdichtsystemen, luchtlagers, magnetische lagers en elastische scharnieren.

Komt er ook een Nederlandse versie?

Het boek is in eenvoudig Engels geschreven. Er is gekozen voor een full color boek. Hierdoor worden de vele foto's en vooral ook de figuren van spanningsconcentraties, drukverdelingen en dergelijke veel duidelijker. De hoge initiële drukkosten van full color zijn moeilijk voor een kleine Nederlandstalige oplage op te brengen terwijl een zwart wit druk kwalitatief veel minder is. Om deze reden wordt voorlopig afgezien van een Nederlandse versie van het boek.

Wat is nieuw?

De meeste hoofdstukken zijn bijgewerkt en uitgebreid met nog meer case studies met in het bijzonder de hoofdstukken Reliability engineering (Ontwerpen op betrouwbaarheid), Fatigue failure and prediction (Ontwerpen op vermoeiingssterkte), Wrijvingsverschijnselen (inclusief berekening van stick-slip, vibratie, resonantie, hysteresis, backlash) en het hoofdstuk Bearings in high tech systems met aandacht voor nauwkeurigheid van deelsystemen in relatie tot systeemspecificaties (error budgetting). De nieuwe versie van het boek wordt gebruikt in de tribologie cursus georganiseerd door het mikrocentrum die door de Nederlandse Vereniging voor Precisie Technologie is gecertificeerd.

Contents

Contents

Chapter 1:   Reliability engineering
Chapter 2:   Failure modes of machine elements
Chapter 3:   Fatigue failure prediction and prevention
Chapter 4:   Rolling contact phenomena
Chapter 5:   Friction phenomena in mechanical systems
Chapter 6:   Wear mechanisms
Chapter 7:   Material selection a systematic approach
Chapter 8:   Lubricant selection and lubrication management
Chapter 9:   Design of hydrodynamic bearings and sliders
Chapter 10: Performance and selection of sealing systems
Chapter 11:  Design of hydrostatic bearings
Chapter 12:  Design of aerostatic bearings
Chapter 13:  Design of flexure based mechanisms
Chapter 14:  Bearings in high tech systems

ADVANCED ENGINEERING DESIGN
LIFETIME PERFORMANCE AND RELIABILITY

Chapter 1: Reliability engineering... 1

1.1 DESIGN FOR LIFETIME PERFORMANCE AND RELIABILITY 1

1.1.1 Introduction 2

1.1.2 History 5

1.1.3 Trends in mechanical engineering design 7

1.1.4 Innovative solutions 9

1.2 RELIABILITY ENGINEERING 10

1.2.1 Component reliability 10

1.2.2 System reliability 16

1.3 FAILURE ANALYSIS 20

1.3.1 Root Cause Failure analysis 20

1.3.2 Failure analysis techniques and procedure 21

Chapter 2: Failure modes of machine elements... 29

2.1 HOW ROLLING BEARINGS FAIL 30

2.1.1 Load patterns and their interpretation 30

2.1.2 ISO 15243 failure mode classification 31

2.1.3 Bearing failures 32

2.2 HOW GEARS FAIL 38

2.2.1 ISO failure mode classification 38

2.2.2 Gear failures 38

2.3 HOW CAM FOLLOWER MECHANISMS FAIL 45

2.3.1 Failure mode classification 45

2.3.2 Cam follower failures 46

2.4 HOW RAIL / WHEEL SYSTEMS AND TRACTION DRIVES FAIL

2.4.1 Failure mode classification 48

2.4.2 Rail / wheel and traction drive failures 48

2.5 HOW JOURNAL BEARINGS FAIL 51

2.5.1 Failure mode classification 52

2.5.2 Journal bearing failures 52

2.6 HOW TRANSMISSION CHAINS FAIL 54

2.6.1 Failure mode classification 54

2.6.2 Chain drive failures 55

2.7 HOW KEY JOINTS FAIL 56

2.7.1 Failure mode classification 57

2.7.2 Key joint failures 57

2.8 HOW SCREW JOINTS FAIL 58

2.8.1 Failure mode classification 58

2.8.2 Screw joint failures 59

Chapter 3: Fatigue failure prediction and prevention 61

3.1 PREDICTION OF THE FATIGUE STRENGTH 62

3.1.1 Factors influencing the fatigue strength 62

3.1.2 Estimating the fatigue strength and endurance limit 68

3.2 DESIGN FOR RELIABILITY 72

3.2.1 Design of dynamically loaded drive shafts 72

3.2.2 Design of dynamically loaded bolted joints 78

3.2.3 Design of dynamically loaded welded structures 87

Chapter 4: Rolling contact phenomena... 97

4.1 STATIC AND DYNAMIC LOAD RATING 98

4.1.1 Nominal point contact 98

4.1.2 Elliptic contact 105

4.1.3 Nominal line contact 107

4.1.4 Contact conformity 109

4.1.5 Geometrical stress concentrations 110

4.1.6 Rolling with traction 111

4.1.7 Permissible contact pressure 113

4.2 ROLLING RESISTANCE 115

4.2.1 Micro slip 115

4.2.2 Plastic deformation 116

4.2.3 Hysteresis losses 116

4.2.3 Spinning 118

4.2.4 Secondary friction losses 120

4.3 ELASTOHYDRODYNAMIC LUBRICATION 121

4.3.1 EHL-line contact 121

4.3.2 EHL-point contact 124

4.4 LOAD RATING OF MACHINE ELEMENTS 127

4.4.1 Static and dynamic load ratings of rolling bearings 127

4.3.2 Static and dynamic load rating of linear rail guides 134

4.4.3 Static and dynamic load ratings of ball screws 138

4.4.4 Surface durability of gears 140

4.3.5 Dynamic load rating of traction drive mechanisms 147

Chapter 5: Friction phenomena in mechanical systems... 155

5.1 REAL CONTACT AREA 156

5.1.1 Surface Roughness 156

5.1.2 Ratio of real contact area and nominal contact area 160

5.1.3 Real contact area versus friction 162

5.2 FUNDAMENTALS OF FRICTION 163

5.2.1 Ploughing 163

5.2.2 Adhesion 165

5.3 CLASSICAL FRICTION LAWS 170

5.3.1 Effect of the nominal contact area 170

5.3.2 Effect of the normal load 170

5.3.3 Effect of sliding velocity 171

5.3.4 Effect of temperature 171

5.3.5 Effect of surface roughness 171

5.4 FRICTIONAL HEATING AND THERMAL FAILURE 172

5.4.1 Nominal contact temperature 173

5.4.2 Flash temperature 181

5.5 FRICTION PHENOMENA IN MECHANICAL SYSTEMS 183

5.5.1 Stick-slip in linear actuators 183

5.5.2 Hysteresis and virtual play 187

5.5.3 Joint Slippage phenomena 189

5.5.3 Side-slip to reduce effective friction 190

5.5.4 Jamming of linear guides 191

5.6 DEALING WITH FRICTION IN MECHANICAL SYSTEMS 192

5.6.1 Variable transmission belt drives 192

5.6.2 Metric thread, fasteners 194

5.6.3 Power screws 199

5.6.4 Interference fits 201

5.6.5 Slide bearings 206

5.7 MEASURING FRICTION 212

5.7.1 Manually 212

5.7.2 Motorised 214

Chapter 6: Wear mechanisms 219

6.1 TWO-BODY WEAR MECHANISMS 220

6.1.1 Adhesive wear 221

6.1.2 Abrasive wear 221

6.1.3 Corrosive wear 223

6.1.4 Surface fatigue 226

6.2 SINGLE-BODY WEAR MECHANISMS 228

6.2.1 Gas erosion 228

6.2.2 Liquid impingement erosion 228

6.2.3 Cavitation erosion 228

6.2.4 Particle erosion 228

6.3 CONTACT CONDITIONS 229

6.3.1 Contact conformity 229

6.3.2 Stationary contact 229

6.3.3 Degree of overlap 230

6.3.4 Contact temperature 230

6.4 WEAR RATE 231

6.4.1 Running-in 231

6.4.2 Calculation of wear rate 232

6.4.3 Classification of the specific wear rate 233

6.5 SELECTING OR CONSTRUCTING TEST APPARATUS 240

6.5.1 Pin-on-disc / Pin-on-ring 241

6.5.2 Pin-on-flat / ball-on-flat 242

6.5.3 Two disk 242

6.6 STANDARDS FOR MEASURING FRICTION AND WEAR 243

6.6.1 Specimen preparation 243

6.6.2 Experiment 244

6.6.3 Reporting 244

6.6.4 Reproducibility 244

Chapter 7: Material selection a systematic approach 247

7.1 MATERIALS FOR SLIDE SURFACES 248

7.1.1 Selection criteria for metals 248

7.1.2 Selection criteria for polymers 252

7.1.3 Selection criteria for technical ceramics 265

7.2 COATINGS AND SURFACE TREATMENTS 268

7.2.1 Where surface treatments are applied 268

7.2.2 Classification of surface treatments 269

7.2.3 Surface treatment techniques 270

7.3 MATERIAL SELECTION: A SYSTEMATIC APPROACH 277

7.3.1 System identification 277

7.3.2 Definition of material selection criteria 277

7.3.3 Pre-selection of materials 277

7.3.4 Experimental setup 278

7.3.5 Selection of the best candidate(s) 278

Chapter 8: Lubricant selection and lubrication management

8.1 LUBRICATION REGIMES 284

8.1.1 Stribeck curve 285

8.1.2 Transition diagram 287

8.2 LUBRICANTS 288

8.2.1 Physical properties 288

8.2.2 Additives 244

8.2.3 Oil supplements 296

8.2.4 Trends in engine and industrial lubrication 298

8.3 TYPES OF LUBRICANTS AND LUBRICANT SELECTION 299

8.3.1 Base oils 299

8.3.2 Biolubricants 300

8.3.3 Food grade lubricants 302

8.3.4 Lubricants for thermoplastics, thermosets and elastomers

8.3.5 Greases 304

8.3.6 Solid lubricants 306

8.3.7 Lubricant selections for specific applications 310

8.4 LUBRICATION MANAGEMENT 312

8.4.1 Grease versus oil lubrication 312

8.4.2 Oil lubrication systems 312

8.4.3 Engine lubrication system 313

8.5 PROACTIVE MAINTENANCE AND OIL ANALYSIS 314

8.5.1 Maintenance engineering 314

8.5.2 Proactive maintenance 315

8.5.3 Causes of lubricant deterioration and their prevention 316

8.5.4 Chemical and physical oil analysis 317

8.5.5 Wear particle analysis 318

Chapter 9: Design of hydrodynamic bearings and sliders

9.1 HYDRODYNAMIC LUBRICATION 324

9.1.1 Reynolds equation 325

9.1.2 Effective surface velocity 329

9.1.3 Film thickness in journal bearings and concentrated contacts 331

9.1.4 Viscous shear 332

9.2 SLIDER BEARINGS 334

9.2.1 Converging wedge 334

9.2.2 Michell bearing 336

9.2.3 Rayleigh step bearing 339

9.2.4 Tapered land pad 342

9.2.5 Curved pad 344

9.3 PLAIN JOURNAL BEARINGS 345

9.3.1 Bearing performance and design 345

9.3.2 Design optimization load versus bearing clearance 353

9.3.3 Design optimization friction versus film thickness 355

9.3.4 Bearings in turbo machinery 356

9.4 VISCOUS DAMPING AND DYNAMIC RESPONSE 357

9.4.1 Dashpot 357

9.4.2 Band on flat 362

9.4.3 Circular disk on flat 364

9.4.4 Circular ring on flat 365

9.4.5 Cylinder on flat 365

9.4.6 Squeeze film dampers 366

9.4.7 Shock loaded journal bearings 358

9.4.8 Dynamically loaded slider bearings 368

9.4.9 Piston ring/liner film development 372

9.4.10 Dynamically loaded journal bearings 373

Chapter 10: Performance and selection of sealing systems

10.1 SEALING SYSTEMS 382

10.1.1 Classification 382

10.1.2 Operating limits 382

10.2 ROTARY SEALS 383

10.2.1 Lip seals, V-rings and O-rings 383

10.2.2 Mechanical face seals 385

10.2.3 Seal face patterns 389

10.2.4 Gap seals 390

10.2.5 Labyrinth seals 391

10.2.6 Magnetic fluid seals 392

10.2.7 Air barrier seals 393

10.3 RECIPROCATING SEALS 393

10.3.1 Reciprocating lip-seals in hydraulics 393

10.3.2 Reciprocating lip-seals in pneumatics 395

10.3.3 Piston guide rings 397

10.3.4 O-rings in reciprocating applications 399

10.3.5 Piston ring-seals in engines 401

Chapter 11: Design of hydrostatic bearings 405

11.1 BASIC METHODS OF OPERATION 406

11.2.1 Methods to obtain bearing stiffness 407

11.2.2 Advantages and limitations of pressurised fluid bearings 408

11.2 DESIGN OF HYDROSTATIC BEARINGS 399

11.2.1 Basic construction elements 409

11.2.2 Hydrostatic thrust bearings with shallow pocket 409

11.2.3 Hydrostatic thrust bearings with tapered film 414

11.2.4 Hydrostatic thrust bearings with capillary restrictor 415

11.2.5 Hydrostatic thrust bearings with orifice restrictor 420

11.2.6 Hydrostatic preloaded thrust bearings 423

11.2.7 Hydrostatic journal bearings with external restrictors 425

11.2.8 Hydrostatic journal bearings with shallow pockets 429

Chapter 12: Design of aerostatic bearings 437

12.1 BASIC METHODS OF OPERATION 438

12.1.1 Methods to obtain bearing stiffness 439

12.1.2 Advantages and limitations of pressurised gas bearings

12.1.3 Structural considerations and kinematics 422

12.2 DESIGN OF E.P. AIR BEARINGS 445

12.2.1 Basic construction elements 445

12.2.2 Design of air bearings with orifice restrictor 449

12.2.3 Design of air bearings with a series annular orifice restrictors 451

12.2.4 Design of air bearings with a series simple orifice restrictors 452

12.2.5 Design of air bearings with partial porous surface 453

12.2.6 Design of shallow pocket air bearings 454

12.2.7 Design of partially grooved air bearings 455

12.2.8 Design of taper and taper-land air bearings 466

12.2.9 Design of journal bearings with porous ring restrictor 457

12.2.10 Design of journal bearings with two porous rings 459

12.2.11 Design of partially grooved journal bearings 460

Chapter 13: Design of flexure mechanisms 465

13.1 BASIC DESIGN PRINCIPLES AND COMPONENTS 466

13.1.1 Design considerations 466

13.1.2 Basic construction elements 470

13.1.3 Dynamic load excitation response 472

13.1.4 Design of hole hinges 474

13.1.5 Micro actuators 476

13.2 DIVERSE APPLICATIONS 477

13.2.1 Flexure cross hinge 477

13.2.2 Piezo parallel guiding with integrated motion amplifier 478

13.2.3 Piezo nano precision XY-parallel mechanism 479

13.2.4 Flexible shaft couplings 480

Chapter 14: Bearings in High Tech Systems 485

14.1 SYSTEM DESIGN 486

14.1.1 Resolution, accuracy and repeatability 487

14.1.2 Error budgeting 489

14.1.3 Errors in translation and rotation 492

14.1.4 Overall system accuracy 494

14.2 ACTUATORS AND CONTROLLERS 494

14.2.1 Stepper motor versus servomotor 495

14.2.2 Rack & pinion versus Traction wheel drive 495

14.2.3 Ball screw versus lead screw 496

14.2.4 Ball screw versus linear motor 496

14.2.5 Iron core versus ironless linear motor 497

14.3 LINEAR GUIDE SYSTEMS 499

14.3.1 Dovetail slides versus rolling guides 499

14.3.2 Rolling guide versus E.P. bearings 500

14.3.3 Air bearings versus hydrostatic bearings 500

14.3.4 Air bearings versus active magnetic bearings 500

14.4 BEARINGS IN MECHATRONIC SYSTEMS 501

14.4.1 Plain journal bearings 501

14.4.2 Jewel bearings 503

14.4.3 High precision ball bearings 507

14.4.4 Spiral groove bearings 508

14.4.5 Magnetic fluid bearings 517

14.4.6 Hydrostatic bearings 517

14.4.7 E.P. Air bearings 518

14.4.8 Magnetic bearings 518

14.4.9 Foil air bearings 520

14.4.10 Hybrid bearings in high speed rotary applications 521

Index

A
Abbé error 481
Abbott-Firestone curve 148
Abrasive wear 29, 211
Accuracy 476
Active magnetic bearings 488
Actuators 482
Additives 284
Adhesion 155
Adhesive wear 30, 211
Aerostatic bearings 427
Aerostatic instability 428
Aftermarket additives 286
Air barrier seals 383
Allowable stress number 128
Aluminium alloys 459
Aluminium-soap greases 294
Amontons-Coulomb law 5
Amorphous polymers 243
Angular contact ball bearings 112
Annular orifices 429
Anti-foam additives 286
Anti-friction coatings 298
Anti-oxidant 285
Anti-wear additives 284
Aquaplaning 274, 365
Archard’s equation 221
Assembly clearance 195
Attitude angle 335
Austenitic stainless steels 214
Average bearing pressure 195

B
Babbitts 240
Backlash 177, 476, 479
Backup bearings 506, 507
Balance ratio 377
Ball screw 484
Ball-on-flat 231
Barus 283
Basic rating life 124
Bath lubrication 301
Bathtub failure 11
Bearing number 337
Bearing stiffness 335
Beauchamp Tower 5, 315
belt drives 181
Bending stiffness 461
Bernoulli 435
Bernoulli equation 400
Bingham-type 294
Biolubricants 290
Biomaterial 249
Bleeding 295
Blok 342
Bolt failure 74
bolt joint 185
Bolted assemblies 75
Bolzmann integrals 246
Boriding 261
Boron Nitride 297
Boundary Lubrication 274
Boundary lubrication additives 284
Brinell hardness 97
Brinelling 215
brittle materials 107
Bronzes 240
Buckling 466
burnishing 149

C
Calcium-soap greases 294
Camshaft 42
Cantilever beams 464
Cantilever loading 481
Capillary restrictor 400, 435
Carburising 261
Case crushing 39
Cavitation 335
Cavitation algorithm 392
Cavitation erosion 217
CD-ROM drive 234
Ceramic ball bearings 257
Chain drive failures 51
Chemical and physical oil analysis 306
Chemical Vapour Deposition 263
Circulation lubrication 301
Cladding 263
Classic friction laws 160
Cleanliness 309
Closed pocket textures 392
Closed system 219
Cloud Point 279
Coatings 258
Cogging 485
Cold welding 211
Cold-welding 210
Compatibility 157
Compatibility: 385
Complex soap greases 293
Compliant mechanisms 456
Component reliability 10
Compounded oils 290
Compressibility 284, 319
Compression ring 391
Concentrated contacts 92
Condition monitoring 304
Cone-on-plate viscometer 310
Coning 376
Consistency 295
Contact angle 112
Contact conditions 218
Contact conformity 103, 218
contact mechanics 91
Contact temperature 219
Corrosion inhibitors 285
Corrosive wear 213
Couette film thickness 324
Couette flow 317
Couette flow film thickness 318
Coulombs friction laws 5
Couplings 473
Crack formation 215, 216
Creep response 245
Critical shear stress 107
Critical speed 495, 510
Cross spring hinge 458
Crystallinity 243
Cumulative damage 84
Current leakage 32
Curved pad 334
Cylinder liner 391
Cylinder Viscometer 280

D
Damage analysis 20
Damping 174, 347
Dashpot 347
Data sheet 233
Deflection curve 460
Degree of overlap 219
Delamination 216
Demulsifiers 286
Design for Environment 9
Design For Reliability (DFA) 68
Detergents 285
Deterministic approach 14
Diamond Like Carbon coatings 264
Differential particle counting 309
Disk brake 204, 234
Dispersancy 306
Dispersants 285
Dovetail slides 487
Dropping point 295
Dynamic error budgeting 482
Dynamic load excitation response 462
Dynamic load rating 124
Dynamic response 347
Dynamic seals 371
Dynamic viscosity 280
d’Arcy law 435

E
E.P. bearings 395
E.P. gas bearings 427
Eccentric piston 352
Eccentricity locus 335
Eccentricity ratio 321
Effective contact radius 103
Effective friction coefficient 181
Effective heat conduction length 168
Effective heat diffusion length 166
effective modulus of elasticity 92
effective radius 93
Effective surface velocity 319
EHL-line contact 116
EHL-point contact 119
Elastic recovery 156
Elastic shakedown 107
Elasto Hydrodynamic Lubrication 274
Electro-thermal actuators 469
Electroless nickel 262
Elliptic contact 99
Endurance limit 61, 64, 65
Engine friction losses 287
Engine lubrication system 302
Engine oils 279
Engineering ceramics 255
Engineering design 9
Engineering plastics 248, 249
Environmental design 9
Environmental Standards 290
EP additives 127
EP-additives 285
EPDM 385
Error budgeting 477, 482
Error mapping 482
Euler definition 319
Excessive voltage 31

F
Fading 162
Failure analysis 19, 25
Failure Analysis (FA) 18
Failure distribution functions 11
Failure Mode Effect Analysis (FMEA) 16
False brinelling 31, 215
Fastener assembly methods 79
Fatigue 3
Fatigue breakage 40
Fatigue corrosion 61
Fatigue crack development 58
Fatigue failure 28
Fatigue life 108
Fatigue strength 63, 64, 108
Fatty oils 290
Fault Tree Analysis (FTA) 16
Ferrofluids 505
Fillet radius 70
Film thickness in journal bearings 321
Finishing techniques 149
Fire point 306
Fissures and cracks 39
Flake pitting 39
Flaking 210
Flash point 306
Flash temperature 171
Flexure hinges 456
Flexure mechanisms 455
Floating seal 390
Flow-restrictor 396
Fluorcarbon Rubber 385
Foil bearings 508
Food and Drug Administration 292
Food grade lubricants 292
Forced circulation lubrication 302
Fracture 33
Fretting corrosion 31, 191, 214
Fretting wear 215
Friction coefficients 189,239,241,251,264
Friction coefficients - polymers 252
friction laws 160
Friction modifiers 284
Frictional heating 162
Fuel economy benefit 282

G
Galling 210, 211
Galvanic coatings 262
Gap seals 380
Gas bearings 427
Gas erosion 217
Gas seals 379
Gear design 132
Gear oils 299
Gears 128
General purpose oils 299
General purpose plastics 247
Generalised Kelvin model 247
Generalized Maxwell model 247
Glass transition temperature 243
Graphite 297
Grease characteristics 294
Grease lubrication 301
Greases 293
Grey staining 38
Grinding 210
Guide elements 384

H
Half-omega whirl 336
Hard anodising 262
Hard chromium 262
Hard disks 234
Hard wearing 222
Hard-facing 263
Hardness conversion 99
Hardness scales and conversion 97
Hazard rate 11
Heathcote slip: 109
Herringbone pattern 501
Herschel-Bulkley model 294
Hertzian contact stresses 95
Hertzian contacts 92
High cycle fatigue HCF 61
High performance plastics 249
High pressure viscosity 283
High shear viscosity 281
Hole hinges 457
honing 149
HP/HVOF 262
hybrid ball bearing 139
Hybrid bearing systems 509
Hybrid bearings 398
Hydraulic fluids 300
Hydraulic oils 299
Hydropad seals 379
Hydrostatic bearings 395
Hysteresis 110, 177, 456, 476
Hysteresis error 478

I
Impedance method 360
Impulse 355
Impulse force 353
Impulse method 360
Indents from debris 32
Induction hardening 260
Industrial lubrication 288
Infant mortality 11
Infinite fatigue life design 61
Inherent orifices 429
Inherent reliability 11
Initial pitting 38
Interference fits 127, 178, 190, 195
Internal clearance 126
Iron core linear motor 484
Ironless linear motor 485

J
Jamming 180
Jewel bearings 491
Joint slippage 178
Joint stiffness factor 76
Journal bearings 335

K
Kelvin model 245
Key joint failures 52
Key ways 71
Kingsbury 326
Kolsterising 262

L
Labyrinth gas seals 381
Labyrinth seals 381
Lame’s equation 190
Lapping 149
Laser texturing 391
Lateral Traction 106
Lead babbitts 240
Lead screw 484
Leave springs 456
Leonardo Da Vinci 5
Life expectancy 13
Limiting shear stress 137
Limiting speed 125
Line contact 101
Linear motor 484
Liquid impingement erosion 217
Lithium-soap greases 293
Load patterns 26
Locating bearing 68
Locus 335
Lord Rayleigh 329
Low cycle fatigue LCF 61
Lubricant deterioration 305
Lubricant life additives 285
Lubricant selection 278, 289
Lubricant selections 299
Lubricant viscosity 278
Lubricants for thermoplastics 292
Lubrication management 301
Lubrication transitions 276
Lubricity 284

M
Machine monitoring 304
Magnetic bearings 506
Magnetic fluid bearings 505
Magnetic fluid seals 382
Magnetic fluids 382
Magnetic levitation 486
Magnets 382
Maintenance engineering 303
Martensitic stainless steel 214
Material selection 237
Maximum Hertzian contact load 95
Maximum tightening torque 185
Maxwell model 246
Measuring friction 201
Mechanical face seals 375
Melting temperature 244
Metal Matrix Composites (MMCs) 241
Metallurgical compatibility 156
Michell bearing 326
Micro actuators 469
Micro elastohydrodynamic lubrication 392
Micro pitting 38
Micro slip 109
Micro welding 162
Micro-EHL 275
Micro-peening 263
Mineral oils 289
Miner’s rule 84
Misalignment 481
Mixed Lubrication 275
Mobility method 360
Moisture corrosion 30
Molybdenum Disulfide, MoS2 297
Moments of inertia 464
Monolithic flexure hinges 470
Mutual solubility 156

N
Naphthenic oils 289
Newtonian fluids 280
Nitriding 261
Nitrocarburising 261
Nitrotec process 261
NLGI consistency number 295
Nominal contact area 146
Nominal contact temperature 163
Non-Newtonian models 294
Non-repeatable runout 236
Non-stationary contact 219
Normal distribution 13
Normal failure distribution 13
Normalised impulse force 355
Notched flexure hinges 458
Nut 189

O
O-rings 375, 387, 389
Ocvirck bearing 340
Oil analysis 304
Oil control ring 391
Oil lubrication 301
Oil lubrication systems 301
Oil monitoring 304
Oil supplements 286
Open system 219
Operating clearance 195
Operational clearance 126
Operational reliability 11
Organo-clay thickener 294
Orifice restrictor 400
Orifices 435
Osborne Reynolds 5, 315
Outgassing 249
Overload breakage 40
Oxidation 305, 307
Oxidative wear 210
Oxide layer 158
Oxidised abrasive 214

P
Pack-aluminising 262
Pack-chromizing 261
Palmgren-Miner 6
Palmgren-Miner rule 84
Paraffinic oils 289
Partial porous surface 430
Particle counter device 309
Particle erosion 217
Peclet Number 166
Periodic load 348
Periodical maintenance 304
Petroleum 289
Phosphate esters 290
Physical Vapour Deposition 263
Piezoelectric actuators 469
Pin-on-disk 230
Pin-on-flat 231
Pin-on-ring 230
Piston rings 362, 391
Piston seals 384
Piston-cylinder lubrication 303
pitch point 130
Pitting 210
Plasma CVD 264
Plastic - plastic combinations 251
Plastic bearings 489
Plasticity index 150
Plate-shaped particles 216
Ploughing 153, 210
Pneumatic hammer 428
point contact 92
Poisseuille flow 317
Polishing wear 210
Polyalkylene glycols 290
Polyalphaolefins 290
Polyisobutylenes 290
Polyurea grease 294
Porous metal bearings 491
Porous surface 430, 435
Pour point 279
Power screws 184, 188
Predictive Maintenance Management 303
Preload a bolt 77, 186
Preloading 126
Pressure angle 126
Pressure feed lubrication 302
Pressure spikes and micro pitting 152
Pressure-viscosity dependency 283
Pressurised fluid bearings 398
Probabilistic approach 14
Probability Density Chart 10
Probability of failure 10
Progressive pitting 38
Prototype testing 229
PTFE 250, 298
PV-value 199

R
R&O additives 285
Rack & pinion 483
Rail-wheel contact 367
Ratcheting 108
Rayleigh step 329
Real contact area 146
Reference speed 125
Reliability 11
Reliability Engineering 10
Reliability factor 124
Relieve cut 70
Repeatability 233, 476
Reporting 233
Reproducibility 233
Resolution 476
Retaining rings 70
Reynolds boundary condition 339
Reynolds Equation 318
Reynolds slip 109, 110
Rheological properties 294
Ringstone jewel bearings 494
Risk Priority Number 16
Rockwell hardness 98
Rod seals 384
Roelands 283
Rolling guidance systems 487
Rolling guide 140
Rolling resistance 109
Root Cause Analysis (RCA) 18
Root Cause Failure Analysis 18
Rotary lip seal 373
Roughness 146
Running accuracy 127
Running-in 220, 276

S
S-N Diagram 61
SAE Viscosity Grades 279
Sassenfeld and Walther 315, 342
Scoring 210
Scratching 36, 210
Screw efficiency 189
Screw joint failures 54, 55
Screw spindle 189
Scuffing 210, 211
Sealing systems 372
Sealing washers 381
Seizure 210, 211
Self-locking 188
Self-lubricating composites 299
Self-lubricating plastics 250
Semi-crystalline plastics 243
Service temperature 243
Servomotor 483
shakedown 107
Shallow pocket bearing 404
Shear modulus 464
Shear strength 63
Shear stress criterion 107
Shore hardness 98
Shot-peening 263
Shotpeening 216
Side-slip 179
Single body wear 210, 217
Sintered metal bearings 490
Sintered metals 241
Slip equation 181
Slip front 178
Slippage 178
Slot feeding 429
Slumpability 295
Smearing 210
Solid lubricants 296
Solidification 284
Solidification pressure 137
Sommerfeld 315
Sommerfeld boundary condition 338
Spalling 39, 210, 216
Specific wear rate 221
Specimen preparation 232
Spiral groove bearings 496
Splash lubrication 301
Spring balance 201
Spring materials 459
Spring stiffness 465
Squeaking 106
Squealing 106
Squeeze film dampers 356
Stability 503
Stainless steels 214
Standard deviation 13
Standard Solid model 246
Standardised tests 229
Starved lubrication 362, 392
Static load rating 96, 122
Stationary contact 218
Stationary heat flow 164
Stepped shafts 69
Stepper motor resolution 477
Stick- and slip zone 109
Stick-slip 173, 177, 251
Stick€slip 479
strain recovery 246
Strain response 245
Stress concentration factor 59
Stress corrosion 61
Stress relaxation 246
Stress response 245
Stress-relaxation 246
Stribeck curve 120
Stribeck-curve 275
Subsurface fatigue 28
Subsurface initiated cracks 37, 45
Sulphurizing 261
Super-finishing 149
Surface durability 128, 132
Surface energy 156
Surface Fatigue 216
Surface hardening 260
Surface roughness 146
Surface texturing 391
Surface topography 392
Surface treatments 258
Surface-initiated fatigue 29
Synthetic esters 290
Synthetic oils 289
System reliability 15

T
Tapered land pad 332
Technical ceramics 255
Test apparatus 230
Thermal expansion 480
Thermal micro actuators 469
Thermo-chemical wear 210
Thermoplastics 242
Thermosets 254
Thin-film approach 317
Thread lubricants 185
Thread shear 187
Three-body wear 210
Thrust washer 231
Tightening torque 184
Tilted plane 202
Tire width 205
Tooth bending strength 128, 134
Tooth breakage 40
Tooth end breakage 41
Torsional stress 82, 186
Total Acid Number (TAN) 307
Touchdown bearings 506
Tower 5
Traction drive mechanisms 136
Traction wheel drive 483
Transient heat flow 165
Transition diagram 277
Transmission torque 190
Trend monitoring 304
Trends in machine design 7
Tresca’s shear criterion 63, 95
Tresca’s yield criterion 107
Tribology 3
Tribometer 230
Tube expansion 367
Turbine oil 300
Two disk tribometer 231
Two roller tribometer 231
Two-body wear 210

U
Ultimate tensile strength 63
Uncertainty 482
US Department of Agriculture 292

V
V-block bearings 495
V-pivot jewel bearing 493
V-ring seals 375
Variable amplitude loading 84
Vegetable oils 289
Vibrating rotor 336, 339
Vibration 126, 173
Vickers hardness 98
Virtual play 177
Visco seals 497
Visco-elastic behaviour 245
Viscosity classification 279
Viscosity Index 282
Viscosity index improvers 284
Viscosity of gases 431
Viscosity-pressure coefficient 121
Viscous damping 347, 348
Viscous seal 382
Viscous shear 322
Viscous shearing 349
Von Mises equivalent stress 464
Von Mises failure criterion 107
von Mises yield criterion 63, 97, 107

W
Water 291
Wave seals 374
Wear coefficient 221
Wear measurement 233
wear mechanisms 210
Wear mechanisms terminology 210
Wear particle analysis 307
Wear rate 220
Wedge effect 318
Weibull failure distribution 12
Welded structures 83
Whirl instability 336
Whirl modes 510
Windscreen wiper 393
Wipers 384
Wire springs 456
Wöhler 6
Wohler diagram 61
Work-hardening factor 132
Worm-gear oils 299
Wrap angle 182

XYZ
Yield strength 63