Viscous heating — the series · Fluid Flow & Aerodynamics

How hot seven films get. The peak temperature rise inside the film itself, on a logarithmic axis, for seven lubricated contacts with ordinary engineering numbers. A journal bearing runs tens of kelvin above its own housing, which is why lubrication systems are designed around heat rather than around load; a water-lubricated bush runs at a hundredth of a kelvin, because water conducts six hundred times better per unit of viscosity. The air bearing is marked: its gap is smaller than air's mean free path, so its film is not a continuum at all.

The film that heats itself

The oil in a bearing is not at the temperature of the metal around it. It is tens of kelvin hotter, the rise contains no length whatever, and whether the heating runs away or settles down depends on something that is not a property of the oil at all — whether the machine driving it holds the speed or holds the force.

part 1 · viscous

A film just past its fold lingers where the fold was. The temperature excess at the middle of a sheared film, scaled by the temperature over which the viscosity falls by e, against time in thermal diffusion times, switched on from rest at five stresses either side of the fold. Below the fold the film settles. Just above it the film climbs to the fold's own centre temperature, 1.19, lingers there as if it had found a steady state, and only then runs away — the longer the closer it is to the fold.

A lost steady state still holds the film

Push a self-heating oil film one per cent past the stress at which it can no longer settle and it does not run away at once. It warms to the temperature the vanished steady state would have had, sits there as if nothing were wrong, and only then goes — after a delay that grows as one over the square root of the overload, and during nearly all of which the load could still be taken back.

part 2 · viscous

Where a motor's line crosses the film's own characteristic. The stress a self-heating film carries against the speed it lets one wall slide past the other, both scaled, for every steady state (solid): it rises while the film is cool, peaks at the fold and falls as the film heats and thins. A motor's torque falls along a straight line as its speed rises (dashed), and the film runs where the two cross. A stiff drive crosses once. A soft drive, shallower than the falling limb's steepest slope, 0.0738, can cross three times. A drive held at a fixed stress is a flat line, and at the fold's stress it only touches.

A motor turns the runaway into a jump

A self-heating oil film has a fold at fixed stress and none at fixed speed, and a real motor is neither: its torque falls along a line as its speed rises. Put that line across the film's own torque–speed curve and the runaway disappears for any motor at all. What replaces it depends on the line's slope. A drive softer than one fourteenth of the cold oil's resistance jumps to a hot state and keeps a memory of the load; a stiffer one does neither. And the boundary between the two falls exactly where the motor is turning at a quarter of its no-load speed, which no motor near its rated speed can reach.

part 3 · viscous

Every rotor lands on the same hot state, later and more smoothly. The centre temperature against time, on a logarithmic axis, for a soft drive five per cent past its fold switched on from rest, with rotors of four inertias. Each climbs, lingers and jumps, and each ends at the hot operating point without overshooting it. The time to pass three e-folds is 7, 16, 101, 948 diffusion times for M = 0, 0.1, 1, 10.

A rotor's inertia slows the jump and cannot make it ring

Give the motor driving a self-heating oil film a rotor that has to spin up, and there are two clocks: the film's diffusion time and the rotor's. Two clocks are what an oscillator is usually made of, and this pair cannot make one. Every eigenvalue stays real at every inertia, because the film and the rotor only ever push each other the same way. What inertia does instead is add its own delay to the film's, and in a real machine, where the rotor is hundreds of times slower, the delay past the fold is almost entirely the rotor's.

part 4 · viscous

An S-shaped set of states and a slow variable that crosses it. The film's steady mean temperature against the housing's, on the cool and hot branches of operating points, with the line on which the housing is in equilibrium with the film, at a derating of 0.22 per unit. Between housing temperatures 1.24 and 1.59 both branches exist. At the derating the essay uses, 0.22, neither meets the equilibrium line there: on the hot branch the housing is always warming, on the cool branch always cooling, so the film runs round the loop drawn over them, jumping at each fold.

A slow sensor makes the bearing cycle

Derate the motor driving a self-heating oil film on the temperature of its housing, which warms over minutes, and a protection meant to hold the bearing cool instead makes it cycle for ever: jump hot, warm the housing until the hot state is lost, drop cool, let the housing cool until the cool state is lost, jump again. The period belongs to the housing, the amplitude belongs to the film, and the derating strength decides only whether the cycle happens at all.

part 5 · viscous

A warm bush stops the bearing hunting

A bearing whose motor is derated on its housing's temperature can hunt, jumping between a cool film and a hot one on the housing's clock. Let the bush warm with the housing, and a second feedback joins the first, of the kind that usually makes things run away. It does the opposite: a warm wall is a stiffer drive, the stiffening closes the S the cycle runs round, and past a bush coupling of about a third the bearing settles, warm and derated, however the protection is set.

part 6 · viscous

A slow bush leaves the bearing hunting, a sixth faster. The film's mean temperature excess over two cycles of a bearing hunting under a derating of 0.2 with a fifth of the housing's excess reaching the bush, for a bush that follows the housing instantly and one ten housing times slow. Both jump between a cool film and a hot one; the instant bush's period is 0.347 housing times, the slow bush's 0.291. The slow bush holds the walls at the cycle's mean, and the film's jumps are the same size.

A slow bush quickens the hunt it cannot start

A bearing's bush warms with its housing and makes the drive stiffer, and past a coupling of about a third it stops a derated bearing hunting. Give the bush a time of its own and the obvious fear is that the lag reopens the hunt. It cannot: whether a bearing hunts is decided by where its equilibrium sits, which no lag can move, and a lag on a positive link cannot make a settled state oscillate. What a slow bush does change is the hunt itself, which runs a sixth faster.

part 7 · viscous

A cut deeper than the film's window flips the film twice a cycle; a shallower one leaves it where it is. A protection that trips at a housing excess of 3.0 and resets at 2.6, against the depth of its cut: left, the film's jumps between its branches per protection cycle; right, the cycle's period in housing times. The film has both branches between 0.6496 and 0.7279 of full drive, so a cut past 0.35 leaves it only the cool one. cut 0.3: never resets; cut 0.34: 0 flips, period 1.85; cut 0.36: 2 flips, period 0.767; cut 0.6: 2 flips, period 0.756.

A trip deeper than the film's window flips the bearing twice a cycle

A smooth derating acts on a bearing's housing temperature as it stands. Most real protections trip instead: they cut the motor at one temperature and restore it at a lower one, a hysteresis of their own laid on top of the film's. Whether the oil then jumps between its cool and hot states is decided by one comparison — the cut's depth against the width of the film's window — and past it the protection's own band sets the rhythm. A trip never lowers the film's peak at all; it only protects the housing, and a deep one buys that with a plunge to the cool branch twice in every cycle.

part 8 · viscous