1
Kamatics Hydro Pintle Bearing Presentation
Kamatics CorporationPO Box 3Bloomfield CT. 06002(860) 243-9704www.kamatics.com
Revised 12/3/11
This document includes technical data as defined by ITAR 120.10 and is subject to export licensing requirements of the U.S. Department of State – prior written authorization is required for export or re-export
Kaman Corporation
Kaman IndustrialTechnologies
Distribution
Aerostructures Precision Products Helicopters Kaman SpecialtyBearings
Aerospace
KAMANCORPORATION
Kamatics
RWG Frankenjura
K-MAX
SH-2
Structural andIntegration
Subcontracting
Missile and Bomb Fuzing
Memory and Instrumentation
Major Structural Subcontracting -
Jacksonville
Kaman Corporation
Kaman Composites
Wichita, KS
Brookhouse, U.K.
Middletown & Orlando Brookhouse, U.K. & Wichita
Kamatics Seattle Office
Kamatics First Application in 19651st application in 1965 on the Servo Flap Bearing on the Kaman SH2 Helicopter
Original Bearings corroding, swelling and seizing in the marine and high humidity environment
Kaman engineering solves the problem using Carbon/Ceramic sphericals.
Kamatics is incorporated. KAron bearings developed shortly afterwards to solve bearing problems on aerospace, marine, nuclear and industrial applications
KAron Self Lubricating SystemsKAron is a homogeneous combination of a self adhering base polyester resin, Teflon and other fillers to enhance the liner performance under different load, temperature and coefficient of friction requirements. The KAron can be bonded to a wide variety of materials.
The base polyester resin is the main load carrying portion of the liner
The Teflon is the main ingredient for controlling the coefficient of friction
The proprietary fillers enhance the load and temperature capabilities
The higher the percentage resin the greater the load capacity
Teflon
Increasing the TFE content lowers the friction but also reduces the load capacity
Polyester Resin
Other Fillers
Specific fillers are used enhance specific characteristics of the liner
Adhesive
Friction
KAron BX
Ingredient &processimprovements
KAron Characteristics• Self-Lubricating (No maintenance required)• Homogenous - uniform wear rates & friction• 100% Bond, Non Peelable• Excellent fluid compatibility• Excellent abrasion resistance• Machinable (.005 to .040 depending on the substrate and operating loads)
• High Load Plus Excellent Anti Fretting properties • Does not swell or lose its hardness in fluids• Excellent wear rates • Grit resistance. The tight tolerances prevents large particles from entering system.• KAron hardness of RC90 M Scale limits embedability of fine particles • Thin KAron on Cu/Ni/Sn (Toughmet) or bronze alloys increases load capacity
KAron Bushing Advantages Specific liners for wide variety of applications. 100% Bond, Non peelable. Able to withstand
installation damage. KAron has a high load capacity so the reduced load area is not an issue
KAron is harder than most TFE liners, limited embedability means better wear resistance in a gritty environment.
Machineability, advantages with final installation. Ability to apply thin liner on Cu/Ni/Sn (Toughmet) or bronze alloys
The Journal Bearing Construction:
Oversize Blank, Bearing Surfaces Roughened and Cleaned KAron Applied Oversized and Cured 100% Bond Achieved Final Machining of KAron and Blank Optional Final Machining by Customer Oversize OD Available for Repairs
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Machinable Liner Advantage
• It is Feasible for Back-to-Back Bushing Installations to be Machined After Assembly (Fabric Bearings Cannot be Machined)
• The Desired Running Clearance of .0005 - .002 is Feasible if the Bushings are Machined After Assembly
• Consider for Multiple Lug Installations for Size and Concentricity Control
Before Machining After Machining
KAron LinerSphericals
The injection of the liner into the cavity between the outer race and ball offers many advantages.
• There is no radial swaging pressure which eliminates the issues of over/under pressure possible when swaging the straight outer race over a spherical surface
• With the injection process the KAron bonds to the outer race and conforms to the ball leading to near perfect conformity
• The injection process enables the use of a cathedral cavity which in addition to the adhesion strength of the KAron creates both a bonded surface and a mechanical lock
• The final result is a free moving spherical with minimal clearances right off the production line
KRP Track Roller Advantages No Lubrication Stainless Steel construction Independent radial and axial load capacity Higher load capacity, load is distributed over 40% of
he bearing vs. line or ball contact Higher friction due to sliding vs. rolling but remains
constant for the life of the bearing. (Important to discuss with customer.)
KAron liner on OD of inner race and thrust surfaces
The Track Roller Bearing Construction:
No lubrication Uniform coefficient of friction Seals Independent radial and axial capacity Stainless steel construction Unique self-aligning feature reduces loads on the
track, prevents skidding
Self Aligning Roller
Cam Follower
Track Roller
Standard and Self Aligning Track RollersThe KAron liner system replaces the ball or needles in track rollers and ball bearings.
The Kamatics design is a sliding system versus a rolling system. While higher than a needle or ball bearing it remains constant for the life of the bearing
The Kamatics designs offers greater load carrying ability, an independent radial and axial capability and high misalignment capability
Unique DesignsSide Load Bumpers incorporated in the track roller
Self Aligning feature for track deflections.Operates Smoothly on Uneven or “Wavy”Tracks. Maintains Full Contact on Track
Eccentric Rollers for easier rigging and adjustments
Combination track slider
Large track rollers (36 inch diameter)
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KAron SpecialsCustomer Coated Components
Pre-KAron BlankExtra material on surfaces adjacent to Karon lined
KAron Coated BlankSurfaces adjacent to liner locations coatedto simplify process Finished Machined Part
KAron
15
10,00067
20,000138
30,000207
40,000276
50,000345
60,000414
10038
20093
300149
400204
500260
600316
700371
KAron BHigh Loads
3 Feet per Min..91 Meter per Min.
.10 COF KAron V
High Loads10 Feet per Min.
3.04 Meters per Min..075 COF
T87/T87SHigh TemperatureHigh Frequency50 Feet Per Min.
15.24 Meters per Min..10 COF
KAron VSLow Friction
Flight Control Applications10 Feet per M in.
3.04 M eters per M in.COF .04
Selected Kamatics Liner Systems
Temperature F - C
0
Dyn
amic
Loa
d PS
I- M
pa
The graphs shown indicate the pressure limits for the respective operating temperatures and are for re ference purposes only. Contact Kamatics for assistance in determining the proper liner taking into consideration the pressure , temperature and duty cycle .
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0.01.02.03.04.05.06.07.08.09.10.11.12.13.14.15.16.17.18.19.20
2 4 6 8 10 12 14 16 18 20
KAron B
KAron V
KAron VS
0
Coefficient of FrictionKAron B, V and VS
Bushings and Sphericals
Coe
ffici
ent o
f Fri
ctio
nA
mbi
ent T
empe
ratu
re
Pressure KSI
The coefficient of friction data is a summury of many tests conducted by Kamatics and our customers. Variables such as contamination and temperature can effect the friction for a given application. Please contact Kamatics for more detailed information For track rollers a more appropiate measurement is the "force to roll" versus the coefficient of friction. Please contact Kamatics for more detailed information.
Range of Friction for a Greased M/M Bearing
-John Day Dynamic Run-Friction Factor During Blade Closing
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0 2 4 6 8 10 12 14 16
Blade Angle (Deg)
Fric
tion
Fact
or
JD U8 (11/19/2008) JD U9 (11/19/2008) JD U16 (11/19/2008)JD U8 (03/19/1980) JD U9 (03/26/1980) JD U16 (03/27/1980)
KAron V Bushings
Existing Bronze Bushings
Kaplan Turbine Hub
Friction Comparison
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Dirty Contaminated EnvironmentOperational Experience and Successful Testing
Kamatics Testing: Silted Water
Helicopters Controls: Fine Sand Landing Craft: Salt Water/Sand
Pintle Test: Brackish/Rust Filled Water
AS81820AS81934 BMS3-39
High LoadSlow Speed Good Anti FrettingFriction .10
Aircraft Flaps/SlatsLanding gear Highly loaded LinkagesJet engine controls
Dynamic Operating Pressures to 50,000 psi (345 MPa).Velocities to 3 fpm (1 M/min.)Temp: –100° to 400° F(-73° to >205°C)
MachineableDensity: 1.51 gm/ccRockwell M 95Thickness Range .005 - .060”(.127 – 1.5 mm)
KAron B
Typical ApplicationsCharacteristicsPhysical PropertiesLiner
Aircraft Track Rollers.Marine ApplicationsHydro TurbinesNavigation GatesMotor SportsIndustrial
Dynamic Pressures: 40,000 psi (276 MPa)Velocities: 0 fpm (3 M/min.)Temp: –100° to 300° F (-73° to 150°C)Thickness: .005 to .040”(0.127 to 1.5 mm)COF: +68°F (20°C) 0.03 to 0.08COF: -65°F (-54°C) 0.1 to 0.18
KAron V
Qualified to AS8943High Loads
Moderate Speeds25% Lower Friction
than KAron B
Typical ApplicationsCharacteristicsLiner
Flight ControlsAileronsRuddersElevatorsSpoilersFlaps/SlatsTrack RollersSphericalsLanding GearSteering SystemsHelicopterSwashplate/Gimbal
Dynamic: Pressures to 15,000 psi (103 MPa)Velocities: to 10 fpm (3 M/min.)Excellent low temperature frictionTemp Range –100° to 300° F (-73° to 150°C)Thickness Range .005 - .040”(0.127– 1.5 mm)COF +68°F (20°C) – 0.02 to 0.05COF -65°F (-54°C) – 0.08 to 0.15
KAron VS
EN4538/4539/4540Low Friction @ Low Temp
Lowest Friction of the KAron Liner Systems
Typical ApplicationsCharacteristicsLiner
Hydrofoil Test 30 Years Ago
KAron V Bearings Selected for: Inboard & Outboard Trunnion Forward and Aft Flap Steering Actuators Lower & Upper Kingposts Door hinge bearings Forward Retract Actuator Base
Forward and Aft Flap bushings
0
0.001
0.002
0.003
0.004
0.005
0.006
KR8 Spherical Test Bearings
AS81820 Oscillation Test Max Allowable Wear .0045
0
0.001
0.002
0.003
0.004
0.005
0.006
Mil H5606 @
160F
TT S 735 @110F
Skydrol500 @160F
Mil L7808 @
160F
Mil A8243 @
160F
AS81820 Fluid Test Max Allowable Wear .006
Bearing: KR8 CNGB: Bore (.5) Ball (440C), Outer race (17.4) KAron B
Oscillation Load Test Fluid Compatibility Test+/- 25 Degrees (100 Degrees total) 24 Hour Soak 10,400 lbs. (Approx. 35,000 PSI) +/- 25 Degrees 20 CPM 7,800 lbs. (Approx. 25,000 PSI) Ambient Temperature 20 CPM25,000 Cycles 25,000 Cycles
KAron B AS81820 Qualification Testing KAron BX Now Qualified to AS81820 Type A
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Customer High Performance KAron B Bushing Test
SAE AS 81934 Requirements:35,000 PSI ( 241Mpa)+/- 25 Degrees (100 Degrees total)25,000 CyclesDry/Aircraft FluidsDeicing fluid (Reduced load)
New High Performance Requirements:50,000 PSI (345 Mpa)+/- 25 Degrees (100 Degrees total)25,000 CyclesDry/Aircraft Fluids Deicing fluid (Reduced load)
.0005(.0127)
.001(.0254)
.0015(.0381)
.002(.0508)
.0025(.0635)
.003(.0762)
.0035(.0889)
.004(.0106)
.0045(.1143)
.0009(.02286)
.0006(.01524)
.00065(.01651)
.00093(.023622)
.001(.0354) .00063
(.016002)
.0011(.02794).00065
(.01651)
.005(.127)
DryLD Hyd
Fluid
TT-S-735
Mil-L-78
08Mil-H
-5606
Mil-A-82
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Grease
Water
.0015 inch (.0381 mm) Maximum Wear per High Performance Specification
.0045 inch (.1143 mm) Maximum Wear per SAE AS 81934
Wea
r in
Inch
es (m
m) @
25,
000
Cyc
les
Bushing Dimensions:KAron B.8750 Bore.375 Length17.4 Substrate
Contamination
High Load - Slow Oscillations
The New Bearing Standard
• Increased Loads
• Reduced Allowable wear
• Contaminated Environment
KAron B Results
Low Uniform Wear Rates Under all Conditions
Added Benefits
• Low Friction
• Machineable Liner
• Injection Molded Sphericals
• Excellent Anti Fretting Properties
KAron BX The First of the Next Generation Kamatics LinersQualified to AS81820 Type A High Performance Specification
SummaryImproved ProcessingImproved Wear RatesImproved FrictionImproved Performance
25,000100,000
1,000,000
0100,000200,000300,000400,000500,000600,000700,000800,000900,000
1,000,000
Cyc
les
AS-81820 AS-81820Type A
Karon BX
Performance Standard
Liner Performance Comparison
Karon BX –40X Baseline Performance
New high performance specification
100,000 cycles @ 35,000 PSI (4 x current 81820 requirements)
Kamatics ran additional testing to one million cycles (Dry) Extended contamination testing planned.
40% reduction in friction.
The X processing is now being applied to all the Kamatics liner systems. Similar results are expected.
KAron BXFriction Performance
Hydro Turbine Linkages
Less than .001 Wear Auto lubricated and still severe damage
KAron vs. Greased Bronze At Grand Coulee DamInspected after 10 years of operation
Long periods of static vibrations followed by movement
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Composite Bearings
MIL-B-85560 is a specification for plain and flanged sleeve bearings with a composite substrate and a self-lubricating liner.
Qualification Requirements:
• 40,000 psi (276 MPa) static load
• 20,000 psi (138 MPa) dynamic load
• -65°F (-54°C) to 250°F (121°C) service temperature
• Compatibility with aerospace fluids and marine environments
Qualified to AS 85560
Flap/Slat Side Load PadsSpoiler EdgesLeading/Trailing Edge RibsEngine Cowls/FairingsClevis Link/Beam ProtectionDoor SlidesTurbine Wicket Washers
Thermoset resin matrix with synthetic fibersLaminate construction for strength and durabilityDynamic Operating Pressures to 20,000 psi (138 MPa)Temp Range –100° to 250° F (-73° to 120°C)Wear Strip Thickness .020” (0.5 mm) to .060”(1.5 mm)Plate Thickness .120” (3.0 mm)
P54Composite MatrixSheets/Pads/Strips
Aerospace ApprovedWear/Anti-FrettingImpact Resistant
Protects Expensive Mating Surfaces
Typical ApplicationsCharacteristicsLiner
Navigational Locks•Miter Gate Pintles•Sector Gate Pintles
KAron PintleFeatures
•KAron coated pucks can be replaced and/or repaired
•Clearance between Karon-coatedpucks, installation surface, and themating surface provides path fordebris to exit the load zone
•Copper Nickel Tin substrate provides fail-safe protection
• Can incorporate wear sensing capability
KAron Pintles Puck Sensors
KAron Pintle Mating Materials
Mating pintle component should be constructed from high-hardness corrosion resistance material, such as stainless steel with a hardness of Rc 40 or higher and a mating surface finish of Ra 16 or better.
KAron PintleConfigurations
Pintle (Male Component) Mounted Puck Design
Gudgeon/Pintle Bushing (Female Component) Mounted Puck Design
Pucks of different (cylindrical) ODsizes can be employed to maximizethe effective coated surface area.
Karon V
Puck Substrate: ToughMet
Mating pintle component should be constructed from high-hardness corrosion resistance material, such as stainless steel with a hardness of Rc 40 or higher and a mating surface finish of Ra 16 or better.
Base Substrate: Stainless Steel
Miter Gate Pintle Bearing: MaterialsDalles Lock and Dam, Oregon – Installed 2011
Puck Substrate: Aluminum-nickel-bronze alloy
Karon V
Base Substrate: Aluminum-nickel-bronze alloy
Sector Gate Pintle Bearing West Closure Complex, New Orleans – Installed 2011
KAron Pintle Bearing Pressure Calculation
Kamatics evaluated the bearing pressures that could be present under certain puck-to-pintle base contact conditions. The given pintle load for the Sector Gate was 1,353 kip. The pressure was calculated for the 3 contact conditions shown below (red Karon puck surfaces are loaded surfaces). The static limit load capacity of the Karon V liner system was 55,000 psi.
Bearing Area: 400.92 sq. in.Bearing Pressure: 3,372 psi
Bearing Area: 330.09 sq. in.Bearing Pressure: 4,095 psi
Bearing Area: 259.27 sq. in.Bearing Pressure: 5,214 psi
Condition 1: Condition 2: Condition 3:
• Powertech/Panama Canal Pintle Test
• 200,000 Cycles, Brackish Rusted Water
• KAron Pucks and Low Friction KAron VS Have excellent Results
• Minimal Wear with no damage to the pintle ball
• KAron Puck Design Reduces Costs
12388 - 88th AvenueSurrey, British ColumbiaCanada V3W 7R7
SCALE MODEL TESTING OF KAMATICSNAVIGATION LOCK SELF-LUBRICATING KARONV PINTLE AND KARON VS BUSHING.PDF
Full report available upon request;
KAron Pintle Test
Sector Gate Pintle Bearing West Closure Complex, New Orleans
Miter Gate Pintle Bearing: Dalles Lock and Dam, Oregon
KAron PintlesApplications
Sector Gate Pintle Bearing West Closure Complex, New Orleans – Installed Early 2011
Sector Gate Pintle Bearing West Closure Complex, New Orleans – Installed Early 2011
Miter Gate Pintle Bearing: Dalles Lock and Dam, Oregon – Installed Early 2011
Miter Gate Pintle Bearing: Dalles Lock and Dam, Oregon – Installed Early 2011
Self-Lube Selection Process
Customer Design Considerations
A better Surface finish and hardness improves bearing performance for all types of liner systems
The Basics
Bearing/Housing Envelope, Drawings
Pin Size/Mating Surface (Finish/Hardness)
Life Requirements/Existing Issues
Loads
• Maximum Static (Radial/Axial)
• Maximum and Normal Dynamic
• Vibration or Shock Loads
Movement
• Angle of Oscillation
• Speed (Cycles per Minute/RPM)
• Angle of Misalignment (Sphericals)
Other
• Temperature Range
• Contamination (Type/Frequency)