11 V May 2023

https://doi.org/10.22214/ijraset.2023.52324
 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue V May 2023- Available at www.ijraset.com

Design and Analysis of Fixed-Segment Carrier at

Carbon Thrust Bearing
P.Manikandan1, P.Gokulnathan2, S.Darshis Pream Kumar Simson3, M.Yogesh4, M.Hariprakash5
1
Assistant Professor, 2, 3, 4, 5Under Graduate Student, Department of Mechanical Engineering, VSB College of Engineering Technical
Campus

Abstract: This thesis work aimed to provide a design and analysis of fixed segment carrier at carbon thrust bearing. With
increased the bearing efficiency and reduced the frictional loss and wear resistance. Thrust bearings plays vital role in
submersible pumps. Thrust bearings are fixed bottom of the submersible pumps so total thrust or axial load acting on the thrust
collar. Thrust collar are manufacturing with resin mixed carbon and casting material and the segments are manufacturing with
casting material and stainless steel material. Two types of materials combines to manufacture the segment carrier. The materials
hardness and density properties are different from on materials to another material. If suddenly power cut is happen the total
load acting on thrust collar. The collar under heavy load carbon surface and segment carrier surface are scratched or damaged
the carbon surface. This type of damages are affecting submersible pump. Submersible pumps are fixed with maximum 900 feet
under the boar well but this damages are happen we spend more money to lifting the pump from well and also time is wasted.
Segment carrier segment surface and thrust pad surface in between micron level film thickness. If the loose segment carrier the
loose segment will tilt under the load and vibration of pump. The thrust collar surface is scratched with thrust collar is not rotate
because the thrust collar is fitted with rotating shaft with key way. In this study the segment carrier were made with same
materials and the hardness of the materials is same and making process are compared to normal bearing were reduced. The
segment carrier is made with stainless steel 410 material. The materials are bought a rod or using pattern with investment
casting. After the materials is after completing machining process will goes to hardening and materials surface will go to
grinding process. The segment surfaces are grinded and achieve the required surface finish. The surface finish techniques are
available no of methods. Triondur coating system is more effective than other process. The grinded segment carrier surfaces are
goes to next process of lapping. Here the surface is lapped and get required level of surface roughness. In this process the
surface roughness is get required level. Because the lapping coating ratio is high the material removal and surface roughness is
get more level like 0.2 micron. The diamond powder coating using 100 CRT is lapping process to achieve the required surface
finish. The main purpose of the study is to reduce the bearing damages and frictional loss and wear loss and pump damages.
And increase the pump life and reduce the raw materials usage.
Keywords: Thrust bearing, Hardness value, Surface Roughness value.

I. INTRODUCTION
Submergible pumps are using various fields like ground water lifting, oil lubrication fields, etc. The modern trends pumps are
available in no of verity. But the concept of lifting liquid is all are same. In the agriculture fields the pumps lifts the water 900 feet
or more. The major problem arise the pump coil windings is damaged but the main reason is thrust bearing is damaged. Because the
thrust bearing is fitted bottom element of the pumps so maximum thrust load acting on the thrust plate. The thrust plate is fixed with
rotating shaft with keyway joint at the thrust load suddenly acting the thrust plate carbon was damage. So damaged thrust plate does
not working but the shaft rotate electrical power so the pump coil winding heat produced and damaged. Thrust bearings are
classified majorly two types one is loose segment with segment carrier and another one is fixed segment with segment carrier. The
major problems arise with loose segment with segment carrier because the loose segments are fitted with segment carrier. The loose
segment have two legs and segment carrier is drilled with actual size of loose segment and as per PCD. The segment and segment
carrier was fitted and fixed with bottom of pump after the thrust plate fixed with pump shaft on segment surfaces. At the time of
pump running suddenly power loss happen the total thrust load is acting on the thrust plate so some vibration create the bottom of
pump. That vibration create unequal position of loose segments. So the film layer thickness of the segment surfaces and thrust plate
was changes so unequal flatness is created between the segments and thrust plate. So the thrust plate rotate with different layer of
film thickness so the thrust plate carbon was weared with high friction. Sometimes carbon damages due to 2 thrust load.

©IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 3235
 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue V May 2023- Available at www.ijraset.com

Compared to loose segment carrier fixed segment with segment carrier was good because the segments are fixed so there is no film
thickness difference between segment and segment carrier. The fixed segment carrier is made with two type of material joint
segments are manufacture with SS material and segment carrier are manufacture with Grade cast iron material so two materials are
completed with its operation and fixed there is lot of time was taken and cost also increased due to lack of raw materials. The
machining operation complete the fixed segment carrier complete the three stages. The first stage is grinding on segment surface.
The second stage is lapping on grinded surface of segments. The third stage is polish the lapped surface for good look and high
surface finish. The all the three stages are specified some constrained that are surface rough ness is increases smooth. The grinding
process the material remove high level of good surface finish. After the lapping process diamond powder mixed with mineral water
coating is increase lapping surface. After the polishing the surface finish is highly good compared to above two stages. The common
surface roughness is the grinding stages is 0.1µ to 0.4µ and the lapping stages 0.1µ to 0.2µ and the polishing stage below 0.05µ. The
fixed segment carrier is different material combination so the properties of materials is changed. The SS material hardness different
with GCI material and density of the materials also varied. But same material of fixed segment carrier the materials was same
hardness and same density so the materials property does not changed. And the bearing life is increased and reused so easily avoid
the problems of the submergible pump.

II. MATERIALS AND METHODS

A. Materials Selection of Segment Carrier

Cast iron grade 20 metal is used to manufacturing a segment carrier. Because the material is high strength and hardness and less
temperature produce and less frictional losses after machining. The segment carrier is made directly from castings the chemical
composition are
Table 1: Chemical Properties of Segment Carrier
Chemical Properties
Carbon 3.00-3.50
Silicon 1.80-2.20
Manganese 0.60-0.80
Sulphur 0.00-0.10
Copper 0.20-0.40
Chromium 0.10-0.25
Phosphorus 0.00-0.15

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue V May 2023- Available at www.ijraset.com

Figure 1: Two dimensional view of Segment carrier Figure 2: Three dimensional view of Segment carrier

B. Material Selection of Thrust Pad carbon

SS-416 grade metal is used to manufacturing a segment carrier. Because the material is high strength and hardness and less
temperature produce and less frictional losses after machining. The segment carrier is made directly from castings the chemical
composition are

Figure 3: Tested Specimen

Figure 4: Tested Specimen

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue V May 2023- Available at www.ijraset.com

Table 2
Chemical properties of carbon steel
Properties Grade and specification
Physical properties of grade G10Z for existing carbon G6Z for new carbon properties
properties
Density (gm/cc) 1.75 to 1.85 1.65 to 1.75
Hardness (shore-d) 80 to 90 60 to 70
Compressive strength (kgf/cm) 2000 to 2200 1400 to 1800
Porosity <2 ≤2
Young’s modulus (kgf/cm2) 230×103 200×103

III. RESULT AND CONCLUSION

The performance of the segment carrier was carried out from varying tests conduct. The tests are classified with

A. Hardness Test
Load P = 3000 kg
D = indenter
dia in mm
d = impression
dia on the carrier surface
HP = 2 [ − √ 2 − 2
HP = 2 × 3000 × 10[10 − √102 − 4.32
HP = 6000 / 32
HP = 187.5 BHN
After hardening process the hardness was got 28 HRC.

B. Density Test
Density test are conducted by digital density meter so the value taken from density meter is 7.8912 to 8 g/cc.

C. Pump Test
Initially uniform wear and uniform pressure calculate before the pump test coefficient of friction µ = 0.12 Is constant value.
Consider a single flat collar bearing supporting a shaft
Let,
r1= External radius of the collar
r2= Internal radius of the collar
1) Power absorbed in friction, assuming uniform pressure
We know that total frictional torque transmitted T= 2 / 3 × × 1 3− 2 3/ 1 2− 2 2
T= 2/3 × 0.12 × 1300 × 383−153 / 382−152
T= 4.163×103 N-mm
T= 4.163 N-m

Power absorbed in friction:

P = T.ω
= 2 × /60 /
= 2 × 1440/ 60 /
= 150 /
P = T.ω = 4.163 × 150
P = T.ω = 624.45 watt
P = 0.6244 kW

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue V May 2023- Available at www.ijraset.com

2) Power absorbed in friction, assuming uniform wear

We know that total frictional torque transmitted T= 1 2 × × ( 1 + 2)
T= 2 3 × 0.12 × 1300 × 53
T= 4.134×103 N-mm
T= 4.134 N-m
Power absorbed in friction:
P = T.ω
= 2 × /60 /
= 2 × 1440/60 /
= 150 /
P = T.ω = 4.134 × 150
P = T.ω = 620.1 watt
P = 0.6201 kW

Table 3 Existing product and its results

Test name/ number Ra value after 4 hrs Ra value after 8 hrs Ra value after 12 hrs Ra value after 16 hrs

1 0.11µ 0.21µ 0.25µ 0.39µ

2 0.16µ 0.23µ 0.29µ 0.38µ

3 0.20µ 0.21µ 0.33µ 0.40µ

Hardness test 187 BHN obtained

Density test 7.8914 g/cc obtained

Hardness test 28 HRC obtained

Table 4 New product and its results

Test name/ number Ra value after 4 hrs Ra value after 8 hrs Ra value after 12 hrs Ra value after 16 hrs
1 0.01µ 0.05µ 0.13µ 0.19µ
2 0.00µ 0.07µ 0.11µ 0.17µ
3 0.00µ 0.02µ 0.09µ 0.14µ
Hardness test 187 BHN obtained
Density test 7.8904 g/cc obtained

Hardness test 28 HRC obtained

Table 5 Preparation of bonding mixture

Preparation of bonding mixture

Operation Details of part Grade Maker Mixing Ratio

Hardener HV998
Bonding Petro araldite 5:2
Araldite AV138

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue V May 2023- Available at www.ijraset.com

Figure 5 Thrust pad carbon stress distribution on x plane

Figure 6 Thrust pad stress distribution on y plane.

Figure 7 Thrust pad temperature distribution

Figure 8 Film thickness of segment

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
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Figure 9 Temperature distribution on segment surface

IV. SUMMARY
Fluids tend to stick to most surfaces due to viscosity, and in the case of Kingsbury type thrust bearing, we rely on the fluid sticking
to the surface on the rotating thrust disc. This fluid is then dragged between the thrust bearing disc and the face of the pivot shoe by
centrifugal force, and forms a wedge shaped film. This wedge shaped film is essential for the successful operation of the thrust
bearing. When the bearing is operating correctly there is no contact between the disc and the face of the pivot shoe. The only time
there is contact is when the motor is stopping or starting. This means there should be only negligible wear between the faces – and
no wear while the motor is operating.
The carbon thrust disc and the face of the pivot shoe by a combination of rotational drag and centrifugal force. The pivot point
should be spherical which allows the shoes to rotate or pivot so that the fluid can form a wedge. The shoes need to be loosely
constrained while still free to pivot.
The carbon thrust bearing drags the fluid around in a circular direction, but this fluid also experiences a centrifugal force, which is
pulling the fluid towards the circumference of the bearing. The combination of these 2 forces means that the fluid is circulating and
going outwards at the same time and it has been found that the peak pressure point is somewhere beyond the center in the direction
of rotation. Quite often this is assumed to be on the face of the pivot shoe approximately 75% across the face of the pivot shoe and
75% out towards the circumference. This is known as the 75/75 Rule in Thrust Bearing design and is where the bearing has peak
loading, minimum film thickness, and high temperatures. If the thrust bearing only operates in one direction it is common to offset
the pivot point so it is nearer to the 75/75 point.
Hydrodynamic thrust bearings commonly have 6 pivot shoes because of the difficulty of ensuring that all the shoes share the load
evenly. More shoes increase the likelihood of uneven loading because of variations in dimensions due to mechanical tolerances. The
thrust-bearing disc transmits the axial thrust load from the rotating shaft (rotor) through the fluid film to the stationary pivot shoes.
A typical film thickness under rated thrust load can be 0.03 mm for a high performance thrust bearing.

V. CONCLUSION
This study succeeds to reach the minimum standard of surface finish of the segment carrier and segments. And the load carrying
capacity of thrust bearing in 1000 kgf to 1500 kgf and compare to regular bearing the surface of the thrust bearing. And practically
tested with test rig with different kinds of load with continually. So the breaking point of the thrust collar carbon life is increased.
And thrust collar is tested with test rig with 16 hrs with 4 cycles and result obtained and the thrust bearing crashed with above 16
hrs. After the test the thrust collar is attained low level of damages.
The main purposes of this study is to build the experimental prototype of an fixed segment carrier at carbon thrust bearing device
that give 5 % efficiency on regular bearing.

©IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 3241
 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 11 Issue V May 2023- Available at www.ijraset.com

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