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    Design and performance evaluation of a 3D printed aerostatic bearing concept with high number of micro-orifices
    (Sage Publications Ltd, 2024) Agoren, Gorkem; Dal, Abdurrahim; Karacay, Tuncay
    This study suggests a 3D printed aerostatic bearing concept. The design has a high number of orifices distributed around the bearing to obtain smoother pressure distribution for performance. Inner channels are formed to connect and feed air to each orifice using the advantage of additive manufacturing. The concept is investigated numerically to determine the performance gain of the high number of orifices by calculating bearing stiffness and load carrying capacity. In order to validate the simulation and performance gain an experimental study is conducted by testing Stereolithography (SLA) type 3D printed bearings with various orifice numbers. The bearing stiffnesses and mass flow rates of the specimens are measured, and results are discussed in terms of performance by comparing numerical results. The 3D printed bearings concept has shown promising results in terms of performance while keeping air consumption limited compared to conventional air bearings.
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    Vibration Analysis of a Hybrid Polymer Ball Bearing with 3D-Printed Races
    (Springer Heidelberg, 2024) Dogan, Burcu Kucukoglu; Dal, Abdurrahim; Agoren, Gorkem; Karacay, Tuncay
    BackgroundThe use of polymer bearings in some industries has increased in recent years because of their advantages, such as resistance to dirt and dust, no need for maintenance and lubrication, and chemical resistance, especially in hygienic areas. Additive manufacturing (AD) or 3D printing is also a popular method that makes complex geometric shapes easily produced using polymer material, layer by layer, of the defined component.PurposeThe study aims to investigate the applicability of producing polymer ball bearing with additive manufacturing techniques by experimentally observing the bearing's vibrations, temperature, and rolling resistance.MethodsA set of ball-bearing races-inner and outer-are produced with the stereolithography (SLA) method using polymeric resin and tested under a certain load.ResultsVibrations and load cell data for rolling resistance are analyzed through its lifetime to investigate the evolution of the bearing under the test.ConclusionThe additive manufacturing method could be preferred to produce a ball bearing with limited life.
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    Vibration behavior of a 3D-printed hybrid polymer bearing with outer race defect
    (Emerald Group Publishing Ltd, 2024) Dogan, Burcu Kucukoglu; Dal, Abdurrahim; Agoren, Gorkem; Karacay, Tuncay
    PurposeIn industry applications, polymer hybrid bearings have become widespread in recent years owing to the lack of lubricant requirements, particularly in areas requiring hygiene. The additive manufacturing method gives significant advantages to have complex machinery parts, and it has become popular in the industry in recent years. However, it has some inherent disadvantages caused by layered deposition/addition of the materials, and the probability of the localized defect is much higher than in the conventional manufacturing methods. This study aims to investigate the effect of the outer race defect on the characteristics of vibration and service lifetime of hybrid polymer ball bearings produced with the stereolithography (SLA) additive manufacturing method.Design/methodology/approachIn this study, polymer bearings' races were produced with the additive manufacturing SLA method, and the outer race defect was analyzed with measured vibrations.FindingsThe results show that the additive manufacturing method suggests a practical solution for producing a polymer hybrid ball bearing. On the other hand, the hybrid three-dimensional-printed bearing, which has an outer race defect, worked for approximately 8 h without any problems under a 1 kg load and a shaft speed of around 1,000 rpm. In addition, when there is a defect in the outer and/or inner race of the ball bearing, the crest factor and kurtosis of the vibration are higher than faultless ball bearing, as expected.Originality/valueThis paper provides valuable information on the lifetime and vibration characteristics of polymer hybrid ball bearing produced by means of additive manufacturing.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-06-2023-0183/