표제지
목차
Abstract 12
제1장 서론 14
1.1. 연구배경 14
1.2. 연구의 목적 및 내용 15
1.3. 논문의 구성 17
제2장 베어링 이론 및 소개 18
2.1. 베어링과 윤활 18
2.2. 유체윤활 19
2.3. 페트로프 식 22
2.4. 베어링 라이닝 메탈의 재료 24
2.5. 강재(Backing material) 29
2.6. 베어링의 종류 31
2.6.1. 메인 베어링(Main Bearing) 32
2.6.2. 추력 베어링(Thrust bearing) 34
2.6.3. 크랭크핀 베어링(Crankpin bearing) 36
2.6.4. 크로스헤드 베어링(Crosshead bearing) 38
2.6.5. 가이드 슈(Guide Shoe) 39
2.7. 화이트 메탈 베어링의 제작 방법 40
1) 백킹 소재의 검증(Backing material verification) 41
2) 벤딩(Bending) 43
3) 접합부에 대한 초음파탐상검사(Ultrasonic testing on welding area) 44
4) 열처리과정(Heat treatment) 45
5) 황삭가공(Rough machining before white metal lining) 46
6) 화학적 분석(Chemical Analysis for white metal) 47
7) 경도측정(Hardness test) 48
8) 화이트 메탈 주조(White metal lining) 50
9) 샤머 테스트(Charmers test) 52
10) 현미경 관찰 검사법(Microscopy) 53
11) 황삭 가공(Rough machining) 54
12) 화이트 메탈 면 초음파탐상검사(Ultrasonic testing) 55
13) 외경 가공을 위한 터닝 가공 및 계측(Turning for outer diameter machining & measurement) 58
14) 베어링 커팅(Cut in the center of the ring) 59
15) 직립 보어링 머시인 또는 플레이노 밀링머시인(Joint final milling for bearing crush by vertical boring machine or plano miller) 59
16) 베어링 크러시 측정(Bearing crush measurement on the special jig) 60
17) 수평식 보오링 머시인(Horizontal boring machine:HBM)을 이용한 오일그루브,탭, 홀 등의 최종 가공 61
18) 수평식 보오링 머시인(Horizontal boring machine:HBM)을 이용한 내경가공 61
19) 버와 샤프 에치(Burr and sharp edge) 제거(Deburring) 62
20) 최종 치수 검사(Final dimension inspection in accordance with drawing) 63
21) 침투탐상검사(Penetrant testing:PT) 66
22) 주석 도금(Flash layer) 68
23) 방청(Preservation) 69
24) 포장(Packing) 70
2.8. 화이트 메탈 베어링의 주조 방법 71
2.8.1. 원심주조(Centrifugal Casting) 71
2.8.2. 중력 주조(Gravity Die Casting) 72
제3장 화이트 메탈 베어링의 검사 방법 73
3.1. 화이트 메탈 베어링 제작 중 검사 방법 73
3.1.1. 육안검사(Visual inspection) 74
3.1.2. 화학분석(Chemical analysis) 76
3.1.3. 베어링 형상 검사(Check of bearing geometry) 78
3.1.4. 경도 측정(Hardness testing) 79
3.1.5. 침투탐상검사 (Penetrant testing) 79
3.1.6. 초음파탐상검사(Ultrasonic testing) 80
3.1.7. 3차원 계측(Geometrical measurement) 85
3.1.8. 결합력 확인을 위한 파괴검사(Bonding strength) 86
3.1.9. 철판 검사 성적서(Mill sheet test certificate) 90
3.1.10. 현미경 조직 검사(Microscopy) 91
3.1.11. 베어링 크러시 측정(엔진 조립 전 검사) 93
3.2. 화이트 메탈 베어링 엔진 운전 후 검사 방법 93
① 선박 및 엔진 정보 확인 (Verify ship & main engine information) 95
② 현상 확인 96
③ 베어링 사진 촬영(Taking photos of bearings) 97
④ 초음파탐상검사(Ultrasonic testing) 98
⑤ 침투탐상검사(Penetrant testing) 100
⑥ 치수 검사(Dimension inspection) 101
⑦ 절단 계획(Cutting plan) 102
⑧ 화학 성분 분석(Chemical analysis) 103
⑨ 결합력 확인을 위한 접착력(파괴) 검사(Bond strength) 104
⑩ 미세 구조(Micro structure) 105
제4장 베어링의 초음파탐상검사법에 대한 고찰 106
4.1. 개정 전 M사 초음파탐상검사(Ultrasonic testing) 방법 106
4.2. 개정 후 M사 초음파탐상검사(Ultrasonic testing) 방법 107
① 초음파 탐상기(Ultrasonic testing instrument) 109
② 프로브(Probe) 110
③ 알 에프(Ratio frequency:RF) 모드 111
④ 타임 베이스(Time base) 111
⑤ 게인(Gain) 111
4.3. ISO UT 검사 방법 112
4.3.1. 적용범위 112
4.3.2. 검사원 112
4.3.3. 검사범위 112
4.3.4. 검사장비(Equipment) 113
4.3.5. 시험 114
4.4. 개정 전, 후 M사 초음파탐상검사 방법의 비교 분석 118
4.4.1. 배경 118
4.4.2. 테스트 준비 120
4.4.3. 초음파탐상검사 결과 121
4.4.4. 개정 후 초음파탐상검사 방법으로 인한 문제점 123
4.4.5. 개정 전, 후 초음파탐상검사 비용 비교 128
4.4.6. 결론 130
제5장 베어링 크러시 시험에 대한 고찰 131
5.1. 베어링 크러시 측정 절차 131
5.2. 메인 베어링 크러시 측정 135
5.3. M사의 베어링 크러시 측정 프로그램 138
5.4. 베어링 크러시 측정 시기 143
제6장 결론 145
참고문헌 149
Table 2.1. Bearing materials for white metal & tin aluminum bearings 26
Table 2.2. Coating for white metal & tin aluminum bearings 26
Table 3.1. Result of bonding strength(Chalmers test) 104
Table 4.1. Compared the result between new & old UT method 129
Table 5.1. Bearing crush measuring(60-98MC-C/ME-C) 136
Figure 2.1. Basic conception of fluid lubrication 20
Figure 2.2. Average film pressure 21
Figure 2.3. Coefficient of friction and... 21
Figure 2.4. Unloaded journal bearing used for Petroff's analysis 23
Figure 2.5. White metal micro structure 24
Figure 2.6. White metal(HM07) 24
Figure 2.7. MAN DIESEL A/S, cast, 88Sn-Cu-Cd white metal, HM07 27
Figure 2.8. MAN DIESEL A/S, aluminium, cast, tin-aluminium, AlSn40 28
Figure 2.9. After rolling and welding of backing material 29
Figure 2.10. Bearing section shape & tin aluminum(AlSn40)... 30
Figure 2.11. Section view for large marine diesel engines 31
Figure 2.12. Main bearing for large marine diesel engines 32
Figure 2.13. Thick shell & thin shell design 33
Figure 2.14. Thrust bearing for large marine diesel engines 34
Figure 2.15. Thrust bearing & Thrust plate theory 35
Figure 2.16. Crankpin bearing for large marine diesel engines 37
Figure 2.17. Crosshead bearing for large marine diesel engines 38
Figure 2.18. Guide shoe for large marine diesel engines 39
Figure 2.19. After final machined guide shoe 39
Figure 2.20. White metal bearing production procedure 40
Figure 2.21. Backing material(Specification: JIS G3106 SM490A) 41
Figure 2.22. Mill test certificate for JIS G3106 SM490A 42
Figure 2.23. Bending procedure on bending machine 43
Figure 2.24. After finished Bending and Welding 44
Figure 2.25. Ultrasonic Testing(UT) on joint welding area, if necessary 44
Figure 2.26. Heat treatment(normalizing & stress relieving) 45
Figure 2.27. After rough machining, dimension check 46
Figure 2.28. Chemical analyzer for white metal 47
Figure 2.29. A top view of the bearing_hardness impressions 48
Figure 2.30. Hardness tester 49
Figure 2.31. After hardness test on white metal specimen 49
Figure 2.32. Centrifugal casting on machine 50
Figure 2.33. White metal welding(GTAW) 51
Figure 2.34. A top view of the bearing_charmers test samples 52
Figure 2.35. Before & after charmers test 53
Figure 2.36. A top view of the bearing_microscopically examination 53
Figure 2.37. After white metal lining, rough machining 54
Figure 2.38. UT on machined white metal surface 55
Figure 2.39. Old UT inspection method 56
Figure 2.40. New UT inspection method 56
Figure 2.41. Report of ultrasonic testing(UT) 57
Figure 2.43. Outer diameter measurement 58
Figure 2.42. Outer diameter machining 58
Figure 2.44. Cut in the center of the ring 59
Figure 2.45. Joint final milling 59
Figure 2.46. Bearing crush measurement 60
Figure 2.47. Final machining for oil groove, tap, hole 61
Figure 2.48. In side final boring 61
Figure 2.49. Deburring 62
Figure 2.50. Dimension check 63
Figure 2.51. Bearing thickness check 63
Figure 2.52. Dimension inspection report for lower main bearing 64
Figure 2.53. Dimension inspection report for upper main bearing 65
Figure 2.54. PT(Penetrant Testing) for crosshead bearing 66
Figure 2.55. PT(Penetrant Testing) for main bearing 66
Figure 2.56. PT(Penetrant testing) report for main bearing 67
Figure 2.57. After flash layer(Sn: 0.002~0.003 ㎜) 68
Figure 2.58. Flash layer thickness 68
Figure 2.59. Free length check 69
Figure 2.60. Preservation oil 69
Figure 2.61. Packing 70
Figure 2.62. Centrifugal Casting 71
Figure 2.63. Gravity Die Casting 72
Figure 3.1. Visual inspection 74
Figure 3.2. Shiny face on guide shoe 75
Figure 3.3. Soldering repairing 75
Figure 3.4. Microscope analysis 76
Figure 3.5. Chemical composition & brinell hardness report 77
Figure 3.6. Roughness testing on bearing surface 78
Figure 3.7. Free spread inspection 78
Figure 3.8. Hardness testing 79
Figure 3.9. PT(Penetrant testing) 80
Figure 3.10. Example of (good) bonding on test specimen 80
Figure 3.11. Example of (good) bonding echo 81
Figure 3.12. Example of (bad) bonding on test specimen 81
Figure 3.13. Example of a small area with lack of bonding 82
Figure 3.14. Example of (bad) bonding on the bearing 83
Figure 3.15. Example of a big area with lack of bonding 83
Figure 3.16. Ultrasonic instrument made by OLYMPUS 84
Figure 3.17. Geometrical measurement equipment 85
Figure 3.18. Bonding strength check 86
Figure 3.19. Chalmers test 87
Figure 3.20. Test specimen for bonding strength 88
Figure 3.21. Chisel test 89
Figure 3.22. Bonding test for white metal by using chisel 89
Figure 3.23. Mill sheet test certificate 90
Figure 3.24. Unacceptable porosities 91
Figure 3.25. Acceptable porosities 91
Figure 3.26. Unacceptable FeSn₂ layer 92
Figure 3.27. FeSn 2 crystals (Good condition) 92
Figure 3.28. Bearing crush theory 93
Figure 3.29. Damaged surface on main bearing 96
Figure 3.30. White metal was peeling off 96
Figure 3.31. Taking photos of bearings 97
Figure 3.32. Examination on undamaged surface 98
Figure 3.33. Examination on damaged surface 98
Figure 3.34. Ultrasonic testing report for no. 8 main bearing 99
Figure 3.35. Ultrasonic testing report for no. 5 main bearing 99
Figure 3.36. Penetrant testing for no. 5 & 8 main bearings 100
Figure 3.37. Dimension inspection report for no. 5 & 8 main bearings 101
Figure 3.38. Cutting plan 102
Figure 3.39. Test report from metallic specimen 103
Figure 3.40. Evaluation curves according to white metal thickness 104
Figure 3.41. Un-Etched condition(Acceptable) 105
Figure 3.42. After Etching condition(Acceptable) 105
Figure 4.1. Example of good bonding 107
Figure 4.2. Example of a small area with lack of bonding 108
Figure 4.3. Example of big area with lack of bonding 108
Figure 4.4. Ultrasonic testing instrument(maker: Olympus) 109
Figure 4.5. Olympus V206, 5㎒, normal probe, ø13㎜ single crystal, Delay line DLH-2 110
Figure 4.6. Heavy damped normal probe 111
Figure 4.7. Testing with a back-wall echo 115
Figure 4.8. Testing without using Back-wall echo and... 115
Figure 4.9. Testing without a back-wall echo display of bond 116
Figure 4.10. Testing without a back-wall echo display of bond defect 117
Figure 4.11. After white metal bonding condition 118
Figure 4.12. After final machined white metal bearing 119
Figure 4.13. Final machined main bearing lower side 120
Figure 4.14. DLH-1 probe... 120
Figure 4.15. DLH-1 probe... 120
Figure 4.16. Reference block for white metal bonding test 121
Figure 4.17. After final machined white metal bearing(UT) 121
Figure 4.18. Some scratch on white metal bearing were found (A) 122
Figure 4.19. Some scratch on white metal bearing were found (B) 122
Figure 4.20. Contact mark were found due to used probe 123
Figure 4.21. Good bonding & initial echo 124
Figure 4.22. Small non-bonding 124
Figure 4.23. Good Bonding with specimen 125
Figure 4.24. Non-bonding 125
Figure 4.25. Before cutting white metal bearing 126
Figure 4.26. Old UT with full wave method... 127
Figure 4.27. UT probe A609S cap 127
Figure 4.28. Olympus v206, 5㎒, normal probe 128
Figure 5.1. Bearing crush theory 131
Figure 5.2. Main bearing crush measurement 132
Figure 5.3. Connecting rod bearing crush measurement 133
Figure 5.4. Bearing crush measurement sheet sample 134
Figure 5.5. Example : Tangential oversize of bearing 135
Figure 5.6. Main bearing crush measurement 137
Figure 5.7. Bearing crush measurement program made by M사 138
Figure 5.8. Bearing crush-point check for no. 1 main bearing 139
Figure 5.9. Bearing crush-point check for no. 1 crosshead bearing 141
Figure 5.10. Bearing crush-point check for no. 4 crankpin bearing 142