Figure 2 shows the graphical representation of bearing L10
life vs. the operating bearing setting for a typical (overhung)
pinion bearing mounting.
Figure 2 Calculated Bearing L10 Life vs Operating Setting
The ideal operating setting that will maximize bearing system
life is generally near-zero to slight pre-load.
Manual Bearing Setting
Manual methods are frequently used to set bearings on a variety
of equipment with low-to-moderate volume production
requirements, whereby a less-than-exact, primarily end-play
setting range variation is acceptable. No special tooling, gauges,
charts or fixtures are typically required, but assembler skill
and judgment are necessary. For example, in the case of a
conventional truck non-driven wheel with a single adjusting
nut design (Fig. 3), manual setting involves tightening the adjusting
nut while rotating the wheel until a slight bind is felt.
Then the adjusting nut is backed off 1⁄6-to-1⁄4 turn to the nearest
locking hole — or sufficiently to allow the wheel to rotate
freely with some minimal end-play. The adjusting nut is then
locked in this position. Skill and judgment are required to determine
when the wheel binds slightly in rotation. The more
complicated the equipment, and the bulkier and heavier it is,
so is a greater degree of skill and judgment required.
Figure 3 Truck Nondriven Wheel
For certain complex designs, large equipment, or highproduction
applications, manual setting may be too troublesome,
of inappropriate accuracy and reliability, or too time
consuming. The Timken Company has devised pre-set bearing
assemblies and automated setting techniques as alternatives
to manual setting.
Pre-set Bearing Assemblies
Many applications utilize or require the use of two-row or
close-coupled bearing assemblies. This will depend upon
the design and operating characteristics of the machine (e.g.,
thermal growth effects, high loads, etc.). To facilitate bearing
settings of this type of design, pre-set bearing assemblies are
frequently used. Pre-set bearing assemblies are available in
a variety of forms, styles and arrangements, but for the most
part are typically referred to as spacer bearings (Fig. 4). The
majority of pre-set bearings are manufactured and supplied
with spacer rings “custom-fitted” between the bearing rows
to control the internal clearances (Ref. “2S”- and “TDI”-
types). As such, these customized or “matched” spacers cannot
be interchanged with any other bearing assembly. Other
pre-set assemblies such as “SR”- or “TNA”-types may apply
interchangeable spacers and/or bearing components. Such
interchangeable assembly components are designed to hold
closer control of the critical tolerances that affect bearing setting;
as a result, they can be randomly selected.
Figure 4 Example of Typical Preset Assemblies
Each pre-set bearing is supplied from the manufacturer
with a specified (unmounted) internal clearance or bench
end-play (BEP). This BEP is chosen to provide the desired
mounted setting range for the given application requirements.
The mounted bearing setting range is determined
from this BEP, based strictly on the effect of shaft and housing
fits. Typically only one tight-fitted (shaft or housing) requirement
is applied (i.e., on rotating member). This results
in expected mounted setting ranges of less than 0.008". The
mounted setting range of interchangeable component assemblies
is typically wider than that for “matched” spacer
assemblies. To apply pre-set assemblies in an application,
simply mount and ensure proper clamping of the bearing
components through the spacers.
Typical Pre-Set Bearing Assembly Applications
Pre-set bearing assemblies are widely and frequently used in
many industrial applications. Typically this includes application
in: planet pinions; hitch or linkage positions; transmission
idler gears; fan hub shafts; water pump and idler pulley
shafts; sheaves; conveyor idlers; winch drums, at the fixed
and float positions of mining equipment; propel and swing
drives; and in larger gear box drives.
Automated Bearing Setting Techniques
In addition to pre-set bearing assemblies, Timken has developed
five popular automated bearing setting techniques
(set-right; acro-set; projecta-set; torque-set; and clamp-set)
as alternatives to manual adjustment.
Table 1provides a matrix format of various features of these techniques. Each method’s ability to hold a reasonably controlled
mounted bearing setting “range” is compared on the
first line of this table. These values are simply an indication of
overall variability in setting for each method and have nothing
to do with the “pre-load” or “end-play” setting target. For
example, under the set-right column the expected (probable
or 6-sigma) setting variation — due to control of certain bearing
and housing/shaft tolerances — could range from a typical
minimum of 0.008"–0.014". This range of setting can then
be apportioned between end-play and pre-load to best optimize
the bearing/application performance.
Figure 5 utilizes a typical four-wheel-drive farm tractor design
to demonstrate examples of the common application of
tapered roller bearing setting methods.
The specific definition, theory and formal process for the
application of each technique is discussed in detail in the following
sections.
Figure 5 Application of Automated Bearing Setting Techniques
Set-Right
Set-right eliminates manual setting adjustment of tapered
roller bearings by controlling certain bearing and mounting
system tolerances. The statistical laws of probability are applied
to predict the effect of these tolerances on the bearing
setting. Generally, the set-right method requires closer control
of some shaft/housing machining tolerances, as well as
closer control (with special class and code) of critical bearing
tolerances.
The method considers that each component involved in
the final assembly of a machine has a controllable tolerance
range for critical dimensions. The laws of probability indicate
that combinations of all low tolerances or all high tolerances
will rarely occur in such an assembly. It then follows that for
a “normal tolerance distribution” (Fig. 6), the overall dimensional
stack-up of all parts will statistically tend to be somewhere
in the middle of the total possible tolerance range.
Figure 6 Frequency Curve for a Normal Distribution
The goal of the set-right method is to control only the most
critical tolerances affecting bearing setting. These tolerances
may be completely contained within the bearing or may
involve certain mounting components (i.e., widths A and B
of Fig. 1 or 7, plus shaft OD and housing ID). The result is an
acceptable bearing setting that will occur within a desired
range, with a defined statistical probability/reliability for all
assemblies. (A probable reliability of 99.73% or 6-sigma is typical,
but in higher-volume production a 99.994%, or 8-sigma
reliability, is sometimes required). There are no adjustment
steps required to use the set-right concept; the components
of the machine are simply assembled and clamped.
All dimensions affecting the bearing setting in a machine
assembly — such as certain bearing tolerances, shaft OD,
shaft length, housing lengths, and housing bores — are considered
as independent variables when calculating the probable
range. In Figure 7 both cones and cups are mounted with conventional tight fits and the end-plate is simply clamped
against the end of the shaft.
Figure 7 Machine Assembly
Special set-right considerations:
- The overall calculated bearing setting range can vary
significantly, depending on the bearing K-factor, its
equivalent axial tolerance, and the number of tight-fitted
components applied (i.e., larger with both tight cones
and cups). A review of the application during the design
stage will enable selection of special tolerance-controlled
bearings and assist in optimizing the mounting design for
the smallest probable setting range.
- To control bearing mounting dimensions, the tolerances
of the bearing system mounting dimensions used
in establishing the probable setting range must be
consistently maintained and, in some cases, more tightly
controlled.
- If the probable bearing setting range cannot be tolerated
by the application, and attempts to reduce the larger
tolerances are not practical or successful, then consider
the spin-right variation to set-right.
- The same class and code of bearing must be used for field
service replacement as was used for the initial production.
Spin-right variation of the set-right technique. In some
cases the probable bearing setting range with set-right can
be too large for the application. To reduce this range and
still apply the laws of probability, a technique called spinright
is used. This technique can be applied to applications
that could also lend themselves to “shim-pack” adjustment
(Fig. 16). To apply this method, the existing probable range
is simply divided by a factor of two or three, depending on
which is necessary to result in an acceptable setting range for
the application.
For example, assume the probable bearing setting range
for the design in Figure 1 is calculated to be 0.018" and the application
demands a setting of 0.000" – 0.009" end-play. The
current range must be divided by a factor of two. Thus with
spin-right the desired shim increment (apply shim between
endplate and shaft) would be equal to 0.009" and the following
technique applied:
- Assemble the gearbox without a shim and “spin
check” — without the seal in place — to determine if the
bearings are set with end-play or pre-load. Under the first
spin check, if the shaft spins freely, end-play is present
(Fig. 8) and the bearings are properly set.
Figure 8 1st Spin Check
- If the shaft does not spin freely, the bearings are preloaded.
Then a 0.009" shim must be installed. A second
“spin check” should result in a freely rotating assembly
indicative of end-play.
- If pre-load is the desired setting, the spin-right procedure
would be applied in reverse of the above example: if the
shaft rotates freely, the bearings are not properly set and a
shim of 0.009" would need to be removed.
Typical set-right applications. The set-right technique has
been used for a wide variety of bearing setting applications,
which include: tractor PTO assemblies — especially with
blind end or split housing designs; automotive front-drive
wheels; gear reducer shafts; planet pinions; and sprockets
and torque hub units, as used on construction and mining
equipment.
Acro-Set
This widely used setting technique is based on Hooke’s law,
which states: within the elastic material limit, component
deflections are proportional to the load applied (i.e. F = kx,
where k = system
spring rate). This
method assumes
that total system
deflection of an
assembly will be
consistent and repeatable
for a given
applied load (Fig. 9)
in an application
where parts and
sections of parts are
reasonably uniform
throughout a group
of units.
Figure 9 System Deflection
To establish the method for a given machine configuration,
a dimensional reference condition known as the “deflection
constant” must first be determined. The deflection constant
is simply the (averaged) system deflection, resulting from a
known “set-up” load applied through the bearings, as determined
from the testing of several preproduction units. This
system deflection is typically gauged by measuring a shim
gap (Fig. 10).
Figure 10 Planetary Drive Wheel
The acro-set system constant is then developed; it equals
the deflection constant for a given applied “set-up” load, plus
the desired bearing setting. In production this constant is
added to the measured shim gap to determine the final shim
pack thickness for each unit.
The selection of the final shim pack thickness for each unit
is simplified by use of a shim chart (Fig. 11). The shim pack
thickness indicated on the chart includes the effect of the
previously established acro-set constant. Note that the shim
chart facilitates proper shim pack determination based on
shim gap measurements taken at two positions, 180° apart.
The planetary drive wheel assembly (Fig. 10) will be used to
illustrate the acro-set technique.
Figure 11 TYPICAL ACRO-SET SHIM CHART
- The “set-up” load “P” was established by pretesting and
is applied by 2 cap-screws (180° apart). The applied load
is proportional to the bolt torque. (Commonly, a much
larger “seating” force is first applied and the bearings
rotated to ensure proper assembled positioning of the
components prior to the acro-set shim gap measurement.)
- Rotate or oscillate the bearings while applying the “set-up”
load “P” and measure the shim gap — first at 0° and again
at 180°.
- Select the proper shim pack thickness (from the shim
chart), equal to the measured gap plus the predetermined
acro-set system constant (that was established from pretested
assemblies). The Figure 10 chart averages the two
readings and provides the final shim pack thickness. In
this case, 0.66 at 180° and 0.61 at 0° gives a 0.97-thick shim
pack.
- Install the final shim pack and torque up all cap-screws to
their clamp-up torque.
Special acro-set considerations:
- Bearing “seating” and “set-up” loading is typically applied
with multiple cap-screws (i.e. Load = NT/(dμ) where:
N = # of cap-screws, T = cap-screw torque, d = cap-screw
diameter, and μ = coefficient of thread friction; where
typical μ = 0.17). Commonly, the applied seating force
should be 2–3× Ca (90) and the applied set-up force
chosen as ¾–1× Ca (90) of the lowest capacity bearing in
the system.
- Loose-fitted adjustable component; a loose-fitted
member at the adjustable position is preferred. However,
variations to tight-fitted cups and cones can be made as
described below:
- The use of tight cups in carriers that are loose fitted in
the housing.
- The use of a loose fitted “master” cup or cone for the
bearing setting operation (mean fit compensated for in
acro-set constant).
- Fixture designs with built-in compensation for the tight
fitted member (projecta-set).
- All components essential to the acro-set concept, such as
housing walls and cover plates, must have a fairly uniform
section size in successive production units.
- The design must lend itself to applying a set-up load to the
movable bearing race for adjustment.
- The bearings must be rotated or oscillated while applying
the set-up load.
- The design must also lend itself to gap measurement of the
movable member.
- The thickness of the actual shim pack used should be
verified.
It may be seen from this simplified schematic that projectaset
is basically a method of ‘projecting’ the two faces essential
to measuring the spacer size from an otherwise inaccessible
position to a point where gauging is possible.
- The tapered roller bearing assembly with lower cone
pressed into position on the shaft
- Also lower and upper cups in the housing but without
upper cone
- Spacing element projects lower cone abutment face a
known distance (x) (clear of shaft end)
- Gauging element projects upper cup track the same
distance (x)
- Upper cone in gauging position
- Gauging point (e.g. for low volume, a dial indicator, or for
high volume, an electronic transformer – LVDT) arranged
and pre-set to indicate spacer size (S)
In this schematic, a movable base (H) is shown which, by
the application of a known force, seats the upper cone in its
‘projected’ track, i.e. — the gauging element then giving a direct
reading of the necessary spacer size. In practice, alternative
methods may be used to suit any particular production facilities and requirements; (for instance, a static base with
the gauging load applied by a moving head from the top).
Typical acro-set applications. Examples where the acroset
method has been successfully applied to tapered roller
bearings include: manual transaxles; drop box transmissions;
farm tractor axle assemblies; power take-off units;
planetary pinions; differential and pinion shafts; gear reducers;
and off-highway truck and tractor wheels.
Projecta-Set
The projecta-set technique is similar in concept and application
to acro-set, but adds additional versatility and sophistication
through utilization of a special gauging fixture. This
gauge enables one to “project” an inaccessible shim, spacer
gap, or reference surface, to a position where it can be easily
measured. This gauge typically incorporates the use of a dial
indicator or an LVDT for measured readings. It is also readily
applied in designs where the adjusting component (cone or
cup) is tight-fitted without sacrificing assembly speed or accuracy.
The method (Fig. 12) consists of two key gauging elements:
a spacer sleeve (Ref. C) and a tapered gauging sleeve
(Ref. D), of known (typically equal) design lengths (Ref. X).
These sleeves will project the inaccessible spacer gap beyond
the shaft end.
Figure 12 PROJECTA-SET Concept
To illustrate the projecta-set method, reference a typical
spiral bevel pinion shaft assembly (Fig. 13). In this indirect-
mounted, cone-adjusted design the bearing setting is
achieved through the use of a spacer located between the two
cone front faces. The cups and cones are tight-fitted in this
application; the required gauging steps are:
Figure 13 PROJECTA-SET Gauging Example With Pinion Shaft
- Place the assembled pinion shaft, except for the upper
cone and spacer, on the press table. Position the gauge
onto the upper bearing cup and apply the upper bearing
cone (Fig. 13).
- Activate the press to clamp the gauge through the two
bearing cones. A known axial load is applied through the
bearing cups at this time by the Belleville spring internal
to the gauge. (Note that the press is required simply to
clamp the upper cone in place, against the spacer sleeve,
for proper seating; some gauge designs accomplish this
with a threaded nut design.)
- Oscillate the gauge (handles) to seat the bearing rollers.
The LVDT probes then measure the axial displacement
between the two gauging members and the required
spacer size is displayed on the digital readout.
- The spacer size is determined by the gauge based on the
formula (Fig. 13): S = Z − A + K
Where
S = Spacer size required
Z = Sleeve length (fixed)
A = Variable distance between corresponding diameters on
the tapers of cone and cup locator (“zeroed” dimension
is known)
K = Constant to compensate for system deflection due to
gauge spring load, mean tight cone fit effect (loss of
clearance), and the desired bearing setting
G = Measured gap, which represents the change in distance
“A”; distance “A” includes “G”
Special projecta-set considerations:
- The size, weight, cost and design of the projecta-set gauge
should be reviewed for specific application viability.
Typical gauging cost for an industrial application,
incorporating LVDT and internal gauge springs, is
approximately $10,000 each. To increase set-up efficiency
(for higher volumes over 30,000 assemblies/year), the
designer should consider design/usage of a special
automated press and press fixture to apply the gauge.
- Separate gauges or interchangeable components (i.e. dual
tapers) would be required if various models or shafts of
the same application use a different bearing series.
- An alternate method of field servicing would be required
to set the tapered roller bearings (acro-set is similar and
should be given primary consideration).
Advantages of projecta-set:
- Prevents time-consuming teardowns to change shims or
spacers in an application with tight cone or cup fits.
- It can be readily applied to automated assembly
processes.
- Human judgment is minimized when compared to past
traditional manual methods.
- The use of projecta-set gauges requires minimum training
time.
- The projecta-set method provides consistent and reliable
settings.
Torque-Set
The torque-set method is based on the principle that the
rolling torque in a pre-loaded bearing directly increases as
a function of the applied pre-load force (typically measured
by dimensional pre-load). Laboratory tests have shown that
the torque variation of a new bearing is small enough to effectively
use bearing rolling torque as a basis for predicting/
gauging a consistent dimensional pre-load setting. This relationship
(Fig. 14) is established during pre-testing of several
units and loads. Shims are added or subtracted after initial
bearing rolling torque is measured to satisfy the desired bearing
setting — either end-play or pre-load. A shim chart is normally
used to assist selecting the final shim pack for each unit
(Fig. 15).
Figure 14 Dimensional Preload vs Bearing Rolling Torque
Figure 15 TORQUE-SET Shim Pack Determination
Chart
The steps required to perform the torque-set technique are
outlined below:
- Assemble the unit with a reference (constant thickness)
shim pack that assures a pre-load in the system (Fig. 16).
Note the resulting bearing pre-load will actually differ
for each assembly, depending on the variations in the
accumulated tolerances of the component parts.
Figure 16 Assemble With Reference Shim Pack
- Measure the bearing rolling torque (Fig. 17).
Figure 17 Measure Bearing Rolling
Torque
- Select the final shim pack thickness based on the preconstructed
shim chart (Fig. 15).
- Install final shim pack and complete the assembly by
installing all cap screws (Fig. 18).
Figure 18 Assembly Complete
Figure 19 Worm Gear Reducer
Bearing rolling torque is influenced by rotational speed
and lubricant used. In any application using the torque-set
approach, the lubricant and speed should remain constant.
The most common method of measuring bearing rolling
torque is with a torque wrench. Sometimes a socket can be
used, which fits over a nut on the end of the shaft or, if this is
not possible, a special adapter can be made that fits the end
of the shaft. In cases where the housing can be rotated, the
torque wrench is adapted to the housing to measure rolling
torque.
If a torque wrench cannot be used, a spring scale may be
substituted to measure bearing rolling torque. Using a string
wound around a gear or wheel and a scale, record the pull
force needed to keep the assembly turning. Rolling torque
is calculated by multiplying the radius of the gear or wheel
around which the string has been wound by the pull force.
This step could be avoided by a shim chart, which indicates
pull force vs. shim pack size.
When measuring bearing rolling torque, turn the shaft as
slowly as possible while maintaining smooth rotation.
Special Torque-Set considerations:
-
Ability to measure rolling torque. The design must lend
itself to measuring the rolling torque of the bearings.
Where other components such as seals, piston rings, etc.
contribute to the torque, provisions must be made to
recognize and isolate these torque values from the bearing
rolling torque. An example would be to record the drag
torque of a shaft and seal in an end-play condition, then
“add-on” the required bearing rolling torque for the preload
condition.
-
Ability to “reseat” tight-fitted members.When tight-fitted
members are used for bearing adjustment, provisions
must be made to “re-seat” or back-press that member after
the torque-set load has been applied and the final shim
pack determined.
-
Bearing rolling torque is influenced by rotational speed
and applied lubrication.These should be kept constant
between units. The most common method of measuring
rolling torque is with a torque wrench. When measuring
rolling torque, turn the shaft as slowly as possible
(estimated at 3.5 rpm) while maintaining smooth rotation.
-
Torque-set.Should not be used if there is an unbalanced
load (created, for example, by heavy parts, clutch plates or
caliper brakes); this would cause the torque to vary during
rotation.
-
For field servicing,the torque-set method should not
be used to reapply previously operated (e.g., run-in)
bearings; a new set of bearings or alternate technique
must be used.
Typical torque-set applications.Torque-set has been
used successfully on various industrial and automotive applications.
Typical applications include pinion and differential
shafts, transmission shafts, and gearbox shafts.
Advantages of torque-set:
- Usually, no special fixtures or tooling are required; a
torque wrench or simple spring scale and cord are all that
are needed.
- No shim gap measurements are required; the shim pack is
simply changed to obtain the correct setting.
- This method is useful in equipment where manual
methods are physically impractical or difficult. However, it
may not be practical in very large equipment.
- Torque-set can be applied to field servicing when new
bearings are installed.
Mounting Designs and Setting Devices
Tapered roller bearings can be mounted in various configurations,
and there are a variety of devices available to set the
bearings to the desired end-play or pre-load in an application.
Cone-setting devices.In an indirect mounting, generally
one cone is backed against a fixed shoulder while the other
cone is movable and backed by some setting device.
A slotted nut (Fig. 20) can be used for obtaining the bearing
setting. The nut is locked in place with a cotter pin. Both the
nut and washer should be of sufficient size to give adequate
backing to the cone. Two cotter pin holes in the shaft, spaced
90° apart, are used to obtain twice as many locking-positionsper-
revolution of the nut, and a corresponding, closer bearing
setting. A locknut, tongued washer, and lock-washer can
be used instead of a slotted nut (Fig. 21). (See the Auxiliary
Parts in the Tapered Roller Bearing Guide for other locknut
arrangements.)
Figure 20 Slotted Nut
Figure 21 Locknut
A stake nut (Fig. 22) can be used for setting the bearings;
and peening the thin section into a keyway slot locks it in
place.
Figure 22 Stake Nut
The setting in Figure 23 is obtained with shims and an endplate
held in place by cap screws in the end of the shaft. A slot
may be provided in the end-plate to measure the shim gap.
Figure 23 End Plate
A TDO-type bearing with cone spacer, above the centerline
(Fig. 24) and a TNA-type bearing, below centerline, are manufactured
with a fixed internal setting built into the bearing.
The TDO-type bearing is shown assembled on the shaft with a
cone spacer and clamped against a shoulder by an end-plate.
The TNA-type bearing is assembled on the shaft with the cones
butted together and similarly clamped against the shoulder.
No further set-up provision is required in either case.
Figure 24 TDO and TDA
Cup-setting devices.In a direct mounting, generally one
cup is backed against a fixed shoulder, with the movable cup
positioned by some satisfactory setting device.
A cup carrier (Fig. 25, above centerline) and cup follower
(below centerline) use shims for setting, and the carrier or
follower is held in place by cap-screws.
Figure 25 Cup Carrier and Cup
Follower
Bearings can be set by the use of a selected cup spacer with
the end-plate secured to the housing by cap-screws (Fig. 26).
Figure 26 Selected Cup Spacer
A TDI-type bearing with a cup spacer (Fig. 27) is supplied
with the cup spacer providing a specific, fixed internal setting.
The bearing is clamped by a cup follower through the
cups and spacer against the housing shoulder. No further
setup provision is required.
Figure 27 TDI
Summary
The fact that tapered roller bearings can be set is an advantage
over other types of bearings. Manual setting has been
considered an acceptable approach by many manufacturers
and will continue to be used. The trend, however, is toward
automated bearing setting procedures because of cost and
more exacting performance requirements.
The selection of an automated bearing setting technique is
best made early in the design stage.
But, if the equipment is already designed and built, one or
possibly a combination of setting techniques could be incorporated
to improve setting reliability and reduce assembly
time.
For more information:
Timken
David Novak
Phone: (864) 250-9725
david.novak@timken.com