Item 0803

DESIGN: SynchroLite ~ Special Tool - Rotor - Hub - Bearing - Elastomeric - Composite Shim

Overview:

To produce an elastomeric bearing using an elastomer, carbon fiber and a flexible bonding agent.

July 1, 2000 ~ This is not going to work with a spiral configuration; because individual rigid members are needed so that they can rotate in respect to each other.

Drawing:

 

Note:

Lord used filament wrapped carbon and epoxy in their early shims and may still be using it today. A steel outer member weighed 1.661 lbs. v.s. 0.315 lbs in composite.

Preamble:

Assume a Cartesian coordinate system where Z denotes the vertical axis, X the longitudinal axis and Y the lateral.

Assume an elastomeric cube. Assume also that a rigid square plate is bonded to the top and another to the bottom surfaces of this cube. If a compression force is applied along the Z-axis then the elastomeric cube will expand in both the X-axis and the Y-axis. By inserting non-extensible square shims between and parallel to the rigid square plates the expansion in both the X and Y-axes can be reduced. Note that these shims are required to resist expansion forces in four directions on the two axes, X and Y.

Now:

Assume a Cylindrical coordinate system where Z denotes the polar axis through the center of the cylinder and r denotes the ray (the axis extending from and normal to the polar axis) and theta denotes the azimuth (degree)

Assume an elastomeric cylinder, which has both an outside diameter and an inside diameter. Assume also that a rigid ring is bonded to the top and another to the bottom surfaces of this cylinder. If a compression force is applied along the Z-axis then the elastomeric cylinder will expand in only one axis, the r-axis. By inserting non-extensible round shims between and parallel to the rigid round plates the expansion in the one r-axis can be reduced. Note that these shims are required to resist expansion forces in two directions on the one axes, r. There can be no expansion on the third axis, theta.

In current elastomer bearings with radial, conical and thrust configuration, the shim is of a material that is non-extensible in all three axes whereas it need only be non-extensible in one axis, the r-axis.

Carbon filament in tension is stronger than steel when compared on the basis of weight.

The purpose of the carbon fiber is to cause the force on one open side of the elastomer to offset the force on the other open side of the elastomer. For radial and near radial configurations the size of the two opposing open sides will be fairly equal. For thrust and near thrust configurations they will not be equal and in worst case scenarios one or more layers of carbon cloth might be preferable.

Method of Construction:

For Conical Bearing:

On a flat sheet of resilient material scribe a spiral. The distance between the lines of the spiral, on the r-axis to be based upon the amount of compression load that is imparted to the resultant bearing and the specifications of the resilient material. The start and the finish of the spiral is based upon the angle of the cone, the amount of rotation required and the specifications of the resilient material.

The resilient material is cut along the scribed spiral line now or after the following process.

The resilient material is coated on the top surface with a flexible bonding material. Carbon fibers of a length equal to (or greater than) the distance between lines on the spiral are placed on the bonding material in an orentation that is inline with the r-axis at that location. Additional bonding material is then placed on top of the carbon fiber.

A simple conical mandrel has the profile of the tapered inside diameter of the desired bearing, plus it also has one or both side walls of the desired bearing. The 'flat coil' of resilient material, carbon fiber and bonding material is wrapped around this conical mandrel. The bonding material is then set by time, heat or any other appropriate means.

The side wall located on the smaller diameter end of the mandrel is removed then the elastomeric bearing is removed. 

Alternative:

Substitute thin wires for the carbon fibers and while the elastomer or glue is still in a liquid state create a magnetic field that will cause the wires to align themselves with the desired orientation.

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Last Revised: July 26, 2000