FAQ 12 - Isn't the piston speed of the
5AT going to be too high?
Editor's Note: With 30 inch piston stroke and 6' 2" wheels,
the piston speed at the max. design speed of 125 mph will be 23.8 m/s (24.8
m/s with worn tyres).
David
Wardale responds as follows:
- Whatever the mean piston speed, a piston
always moves slowly close to the end of its stroke and is in fact stationary,
relative to the cylinder, at dead centre. Cylinder liners are known to
wear more at the ends than the centre. These 2 factors are linked. Near
the ends of the stroke there is too little velocity for hydro-dynamic lubrication
to occur - with any piston speed. Conversely where the piston is moving
fast, near the centre of the stroke, hydrodynamic lubrication does occur
and wear is less. The high velocity of the 5AT piston in this zone will
merely accentuate the trend to good hydrodynamic lubrication and low wear
near the centre of the stroke, whilst doing nothing to make it worse at
the end of the stroke where the velocity is always at or near zero.
- The piston head does not touch the liner,
therefore contact is limited to the piston rings and liner.
- The rings are "barrelled" on their
outside diameter and can to a limited extent tilt in their grooves, both
of which favour full hydrodynamic lubrication.
- The rings are very elastic, therefore their
pressure on the liners is low when steam pressure is low, e.g. when drifting.
- Drifting has to be with a limited amount
of drifting steam which carries away friction-generated heat which would
otherwise build up during high-speed drifting.
- The rings and liners are perlitic chromium
cast iron of high quality, which gave excellent results in 3450 ("Red Devil").
- Cylinder lubrication will be such as to
guarantee oil reaching the cylinder liner walls and not simply blown to
exhaust which all too often happened in the past.
- Cylinder oil may have colloidal graphite
added, which greatly reduces friction and wear, or perhaps synthetic oil
specifically for the conditions in a locomotive's cylinders and valves
may be used.
- Drifting steam ensures no abrasive particles
are carried into the cylinders from the blast nozzles, because of no vacuum
occurring in the cylinders. (Note: There will in any case be minimal such
particles would at any rate be minimal with oil firing). Likewise antifoam
ensures no abrasive scale particles can form in the steam in the superheater,
because no water carrying dissolved solids leaves the boiler.
- The reciprocating masses are supported by
the crosshead/slidebar bearing and tail rod, which are easy to lubricate
as they are not subject to steam temperature (and the piston etc. mass
is also very low for reasons of reducing the reciprocating masses, therefore
low bearing pressures).
The above 10 reasons are given to indicate
why no lubrication problem is expected on the 5AT despite its high piston
speed (and it is not so much higher than what has been achieved before,
e.g. the N & W J Class 4-8-4s apparently ran regularly at 90 mph with
70 inch drivers giving the same piston speed that the 5AT would have at
97mph - see note below). The key, apart from
the fundamental item No. 1 in the list, is the taking of so many factors
(e.g. light piston, use of a tail rod, flexible rings, drifting steam etc.)
all of which act to improve lubrication. If you didn't have all these factors
coming together you would have trouble if for any reason (e.g. oil starvation
or excessive bearing pressure) full hydrodynamic lubrication (i.e. the forming
of a proper load-bearing oil film) were not present during the entire piston
stroke. That this may well have happened with first-generation locomotives
is why some idea of limiting piston speed probably developed, but, e.g.
like using 450oC steam (where 400oC was thought the
limit in the past), such previously considered limitations no longer apply
where proper means are taken to overcome them.
Note: According to Philip Atkins in his book "Dropping
the Fire", page 24, one of the Class Js attained a speed of 110 mph
whilst experimentally running on the Pennsylvania Railroad in 1944 with
half worn (5ft 8 ½ inch) tyres. And of course the boiler pressure
of the Js in final form was 300 psi. The 110mph speed reached by a
J is further corroborated in David P. Morgan's book "Steam's Finest
Hour" p61: "As for the J, need anything more be said than that
a comparatively low-drivered 4-8-4 proved herself not only equal to the
mountains but also capable of whipping a 1025-ton test passenger train up
to 110 miles per hour across the Virginia swamps".
Page created 3 May 2004