Welding Technology  ·  Level 6
Thermodynamics And Fluid Mechanics Principles
Chapter 8: Apply the knowledge of viscous flow of fluids
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Viscous flow of fluids is a fundamental concept in mechanical production, especially for technicians involved in systems where fluid movement affects machine performance and product quality. Understanding how viscous fluids behave in various configurations such as pipes and bearings enables technicians to diagnose flow problems, design efficient lubrication systems, and optimize machinery operation. In Kenya, industries ranging from food processing to pharmaceutical manufacturing rely on precise control of viscous fluid flow for consistent output and equipment longevity. This chapter focuses on applying theoretical principles to practical scenarios encountered by mechanical production technicians.

8.1 Flow of viscous flow

A viscous fluid resists being deformed. When one layer of fluid slides over another, a shear force acts between the layers. Newton's law of viscosity states that the shear stress is proportional to the rate at which the velocity changes across the flow:

τ = μ × du ÷ dy

where τ is the shear stress in Pa (N/m²), μ is the dynamic viscosity in Pa·s and du ÷ dy is the velocity gradient in 1/s. The kinematic viscosity is ν = μ ÷ ρ, in m²/s. Lubricating oils, greases, paints and cutting fluids are viscous, and their flow decides pressure losses in pipes, the power wasted in bearings and the thickness of the oil film on a sliding surface. The ISO viscosity grade of an oil, such as ISO VG 46, is its kinematic viscosity in mm²/s at 40 °C. For an oil of density about 870 kg/m³, this is a dynamic viscosity of about 0.04 Pa·s.

This topic covers flow that is laminar: the fluid moves in smooth layers that do not mix. In a pipe the flow is laminar when the Reynolds number Re = ρ × V × D ÷ μ is below about 2000. Other symbols used are the pressure gradient G = −dp ÷ dx in Pa/m, positive when the pressure falls in the direction of flow, and the no-slip condition: the fluid in contact with a solid surface moves at the speed of the surface.

8.1.1 Flow of Viscous Fluid in Circular Pipes

Consider a long straight pipe of radius R and diameter D, with steady laminar flow. A force balance on a cylinder of fluid of radius r and length dx gives the shear stress at radius r:

τ = G × r ÷ 2

The shear stress is zero on the axis and rises in a straight line to a maximum at the wall, τ₀ = G × R ÷ 2. Putting τ = −μ × du ÷ dr and integrating with u = 0 at r = R (no slip) gives the velocity at radius r:

u = G ÷ (4μ) × (R² − r²)

The velocity profile is a parabola. The maximum velocity is on the axis, u_max = G × R² ÷ (4μ), and the mean velocity is half of it, V = G × R² ÷ (8μ). The discharge is:

Q = π × R⁴ × G ÷ (8μ) = π × G × D⁴ ÷ (128μ)

This is the Hagen-Poiseuille equation. Solving for the pressure drop Δp over a length L, where G = Δp ÷ L:

Δp = 128 × μ × L × Q ÷ (π × D⁴) = 32 × μ × L × V ÷ D²

Two results follow. The pressure drop is directly proportional to the viscosity, the length and the flow rate, and it is inversely proportional to the fourth power of the diameter, so halving the diameter raises the pressure drop sixteen times for the same flow. The head lost to friction is h_f = Δp ÷ (ρ × g). Written in the Darcy form, the friction factor is f = 64 ÷ Re.

Worked example: oil of viscosity 0.1 Pa·s and density 900 kg/m³ flows at 1.0 litre/s (0.001 m³/s) in a 25 mm pipe 10 m long.

  • Area: A = π × 0.025² ÷ 4 = 0.0004909 m²
  • Mean velocity: V = 0.001 ÷ 0.0004909 = 2.037 m/s
  • Reynolds number: Re = 900 × 2.037 × 0.025 ÷ 0.1 = 458, so the flow is laminar
  • Pressure drop: Δp = 32 × 0.1 × 10 × 2.037 ÷ 0.025² = 104 304 Pa, or 104.3 kPa
  • Maximum velocity on the axis: 2 × 2.037 = 4.074 m/s
  • Wall shear stress: τ₀ = Δp × D ÷ (4L) = 104 304 × 0.025 ÷ 40 = 65.2 Pa
  • Pumping power to move the oil through the pipe: Q × Δp = 0.001 × 104 304 = 104.3 W
  • Head lost: 104 304 ÷ (900 × 9.81) = 11.8 m of oil

The velocity profile means that the fluid at the wall is slowest and the fluid at the centre is fastest. At r = R ÷ 2 the velocity is three quarters of the maximum. Higher viscosity makes the pressure drop larger, so oil that is cold, and therefore thicker, takes more pumping power through the same pipe.

In practice, fouling or a build-up on the pipe wall reduces the diameter, and because the pressure drop depends on D⁴, even a small reduction makes a large increase in the pressure needed. A rise in pump pressure at the same flow is an early sign of a blocked or fouled line.

8.1.2 Flow of Viscous Fluid through an Annulus

An annulus is the space between two concentric cylinders of radii R₁ (inner) and R₂ (outer). It is found where a shaft runs inside a sleeve and oil is pumped through the gap, and in the tube-in-tube heat exchanger. For steady laminar flow driven by a pressure gradient G, with both walls at rest, the velocity at radius r is:

u = G ÷ (4μ) × [R₂² − r² + (R₂² − R₁²) × ln(r ÷ R₂) ÷ ln(R₂ ÷ R₁)]

The velocity is zero at both walls and rises to a maximum at the radius:

r_m = √[(R₂² − R₁²) ÷ (2 × ln(R₂ ÷ R₁))]

which lies nearer to the inner wall than the middle of the gap. The shear stress is zero at r_m and changes sign there. The discharge is:

Q = π × G ÷ (8μ) × [R₂⁴ − R₁⁴ − (R₂² − R₁²)² ÷ ln(R₂ ÷ R₁)]

The mean velocity is V = Q ÷ [π × (R₂² − R₁²)]. When R₁ tends to zero, the last term vanishes and the equation becomes the Hagen-Poiseuille equation for a pipe. The pressure drop over a length L is Δp = G × L.

Worked example: oil of viscosity 0.1 Pa·s flows in the annulus between a shaft of 10 mm radius and a sleeve of 15 mm radius, with a pressure gradient of 10 kPa/m (10 000 Pa/m).

  • ln(R₂ ÷ R₁) = ln(1.5) = 0.4055
  • Radius of maximum velocity: r_m = √[(0.015² − 0.010²) ÷ (2 × 0.4055)] = √(0.000125 ÷ 0.8109) = 12.4 mm
  • Maximum velocity: u_max = 0.314 m/s
  • Discharge: Q = π × 10 000 ÷ 0.8 × [0.015⁴ − 0.010⁴ − 0.000125² ÷ 0.4055] = 39 270 × 2.089 × 10⁻⁹ = 8.2 × 10⁻⁵ m³/s, or 0.082 litre/s
  • Mean velocity: V = 8.2 × 10⁻⁵ ÷ [π × 0.000125] = 0.209 m/s

For comparison, a solid pipe of 15 mm radius with the same pressure gradient would carry Q = π × 10 000 × 0.015⁴ ÷ 0.8 = 0.00199 m³/s, which is 24 times as much. The shaft takes up part of the space and the fluid is slowed by the shear at two walls, so the flow in an annulus is far lower than in a pipe of the outer size. The result for the annulus is also very sensitive to the gap: a narrow gap passes little oil unless the pressure is high.

8.1.3 Flow of Viscous Fluid Between Two Parallel Plates

Two flat plates a small distance h apart, with a viscous fluid between them, model the oil film in a slider bearing or a seal, and the clearance between a piston and its cylinder when they are laid out flat. Take x along the plates and y across the gap from the lower plate (y = 0) to the upper plate (y = h). For steady laminar flow, the momentum balance is:

μ × d²u ÷ dy² = dp ÷ dx = −G

Integrating twice gives u = −G × y² ÷ (2μ) + C₁ × y + C₂, and the constants are found from the speeds of the plates. The three cases of the curriculum follow, from the simplest one.

8.1.3.1 One plate moving and other at rest

The lower plate is at rest and the upper plate moves with speed U. With no pressure gradient (G = 0) the velocity varies in a straight line:

u = U × y ÷ h

This is Couette flow. The shear stress is the same at every level, τ = μ × U ÷ h, and the force on the moving plate is F = τ × A for a plate area A. The flow per metre of width is q = U × h ÷ 2, because the mean velocity is U ÷ 2.

When a pressure gradient is also present, the two effects add:

u = U × y ÷ h + G ÷ (2μ) × y × (h − y)

and the flow per metre of width is q = U × h ÷ 2 + G × h³ ÷ (12μ).

Worked example: oil with μ = 0.08 Pa·s fills a gap of h = 2 mm and the upper plate moves at U = 0.5 m/s.

  • Shear stress: τ = 0.08 × 0.5 ÷ 0.002 = 20 Pa
  • The velocity at the mid-gap is 0.25 m/s (half of the plate speed)
  • Flow per metre width: q = 0.5 × 0.002 ÷ 2 = 0.0005 m³/s
  • With a pressure gradient of 5000 Pa/m added: the velocity at mid-gap is 0.25 + (5000 ÷ 0.16) × 0.001 × 0.001 = 0.25 + 0.03125 = 0.281 m/s, and q = 0.0005 + 5000 × 0.002³ ÷ (12 × 0.08) = 0.0005 + 0.0000417 = 0.000542 m³/s

8.1.3.2 Both plates at rest

Both plates are fixed and the flow is driven only by the pressure gradient. With u = 0 at y = 0 and y = h:

u = G ÷ (2μ) × y × (h − y)

The profile is a parabola with its maximum midway between the plates:

  • Maximum velocity: u_max = G × h² ÷ (8μ)
  • Mean velocity: V = G × h² ÷ (12μ), which is two thirds of u_max
  • Flow per metre width: q = G × h³ ÷ (12μ)
  • Wall shear stress: τ₀ = G × h ÷ 2
  • Pressure drop over a length L: Δp = 12 × μ × L × V ÷ h²

The flow is proportional to the cube of the gap, so halving the gap cuts the flow to one eighth for the same pressure gradient.

Worked example: oil with μ = 0.08 Pa·s flows between fixed plates 2 mm apart under a pressure gradient of 5000 Pa/m.

  • u_max = 5000 × 0.002² ÷ (8 × 0.08) = 0.03125 m/s
  • V = 5000 × 0.002² ÷ (12 × 0.08) = 0.0208 m/s
  • q = 5000 × 0.002³ ÷ (12 × 0.08) = 4.17 × 10⁻⁵ m³/s per metre of width
  • τ₀ = 5000 × 0.002 ÷ 2 = 5 Pa

8.1.3.3 Both plates moving in opposite directions

The upper plate moves at speed U₁ in the positive direction and the lower plate moves at speed U₂ in the opposite direction. With no pressure gradient the velocity changes in a straight line from −U₂ at the lower plate to +U₁ at the upper plate:

u = −U₂ + (U₁ + U₂) × y ÷ h

The shear stress is constant, τ = μ × (U₁ + U₂) ÷ h, and it is the relative speed of the plates that matters. The velocity is zero at y₀ = U₂ × h ÷ (U₁ + U₂), which is the mid-gap when the speeds are equal. The net flow per metre of width is q = h × (U₁ − U₂) ÷ 2, which is zero for equal speeds, because the fluid carried forward by one plate is carried back by the other. If a pressure gradient G is added, the term G ÷ (2μ) × y × (h − y) is added to the velocity.

Worked example: oil with μ = 0.08 Pa·s fills a gap of 2 mm. The upper plate moves at 0.3 m/s and the lower plate moves in the opposite direction at 0.2 m/s.

  • Shear stress: τ = 0.08 × (0.3 + 0.2) ÷ 0.002 = 20 Pa. This equals the stress when one plate moves at 0.5 m/s with the other at rest, since only the relative speed counts.
  • The fluid velocity is zero at y₀ = 0.2 × 2 ÷ 0.5 = 0.8 mm from the lower plate.
  • Net flow per metre width: q = 0.002 × (0.3 − 0.2) ÷ 2 = 0.0001 m³/s.

8.1.4 Kinetic energy correction and momentum

In pipe flow the velocity differs from point to point, but calculations use the mean velocity V. The kinetic energy and the momentum of the flow are larger than the values worked out from V alone, so two correction factors are used.

  • The kinetic energy correction factor α is the actual rate of kinetic energy flow divided by ½ × ṁ × V², where ṁ = ρ × Q is the mass flow rate. The kinetic energy flux is then α × ½ × ṁ × V².
  • The momentum correction factor β is the actual rate of momentum flow divided by ṁ × V. The momentum flux is then β × ṁ × V.

For the parabolic velocity profile of laminar flow in a pipe, u ÷ V = 2 × (1 − r² ÷ R²), and integrating over the area gives α = 2 and β = 4 ÷ 3. For turbulent flow the profile is much flatter and both factors are close to 1, only a few per cent higher.

The energy equation for laminar flow between two sections 1 and 2 of a pipe, in terms of head, is:

p₁ ÷ (ρg) + α × V₁² ÷ (2g) + z₁ = p₂ ÷ (ρg) + α × V₂² ÷ (2g) + z₂ + h_f

For a pipe of constant diameter the two kinetic energy terms are equal, cancel, and the pressure drop equals the friction loss. The factor α matters where the velocity changes, such as at the entry from a tank or at a change of diameter.

Worked example, for the oil in the 25 mm pipe above (ṁ = 900 × 0.001 = 0.9 kg/s, V = 2.037 m/s):

  • Kinetic energy flux using V alone: ½ × 0.9 × 2.037² = 1.868 W
  • Actual kinetic energy flux: 2 × 1.868 = 3.735 W, twice as large
  • Momentum flux using V alone: 0.9 × 2.037 = 1.833 N
  • Actual momentum flux: 1.3333 × 1.833 = 2.445 N

The momentum flux is used to find the force on a pipe bend, a nozzle or a valve, where the change of momentum of the flow produces a force on the part, which the supports and welded joints must carry.

8.1.5 Power Absorbed in Viscous Flow

Viscous shear turns mechanical energy into heat. The power absorbed is the viscous force multiplied by the velocity at which it acts. It must be supplied by the pump or the motor, and it appears as a rise in the temperature of the fluid and of the parts.

Power absorbed in a pipe. The pump has to overcome the pressure drop, so:

P = Q × Δp = 128 × μ × L × Q² ÷ (π × D⁴)

For the oil pipe in the worked example, P = 0.001 × 104 304 = 104.3 W. Doubling the flow raises the power four times for laminar flow, since the power depends on Q².

Power absorbed between sliding surfaces. For a film of thickness h between a surface of area A moving at speed U and a fixed surface, the shear force is F = μ × A × U ÷ h, and the power is:

P = F × U = μ × A × U² ÷ h

For example, a plate of area 0.2 m² slides at 2 m/s over an oil film 1 mm thick with μ = 0.1 Pa·s.

  • Shear stress: τ = 0.1 × 2 ÷ 0.001 = 200 Pa
  • Force: F = 200 × 0.2 = 40 N
  • Power absorbed: P = 40 × 2 = 80 W

The viscous force on any surface can be found from F = μ × A × (du ÷ dy). For an area of 0.02 m², a viscosity of 0.1 Pa·s and a velocity gradient of 50 s⁻¹, the force is 0.1 × 0.02 × 50 = 0.1 N. The power is this force multiplied by the speed at which the surface moves.

The power loss is smaller with a thinner oil, a wider film and a lower speed. A lubricant is chosen to keep the film thick enough to carry the load while wasting as little power as possible.

8.1.6 Viscous Resistance of Journal Bearings

A journal bearing carries a rotating shaft (the journal) in a sleeve. A thin film of oil fills the clearance c between the shaft and the sleeve. When the load is light, the shaft runs nearly concentric in the sleeve, and the oil film can be treated as a Couette flow between a moving surface (the shaft) and a fixed surface (the sleeve). This is Petroff's analysis.

Let the shaft have diameter D, the bearing length L, the radial clearance c and the speed N in rev/s. The surface speed is U = π × D × N. Then:

  • Shear stress in the film: τ = μ × π × D × N ÷ c
  • Friction force on the shaft surface: F = τ × π × D × L
  • Friction torque: T = F × D ÷ 2 = π² × μ × N × D³ × L ÷ (2c)
  • Power lost: P = 2π × N × T = π³ × μ × N² × D³ × L ÷ c

The resistance is greater for a more viscous oil, a higher speed, a larger and longer shaft and a smaller clearance. In real bearings the shaft is displaced sideways by the load, which makes the film thin on one side and thick on the other, and this wedge-shaped film supports the load. The concentric result gives a good estimate of the friction torque, and the sizes of the clearance and viscosity control both the load capacity and the resistance.

Worked example: a shaft of diameter 100 mm runs in a bearing of length 80 mm with a radial clearance of 0.05 mm at 1500 rev/min (25 rev/s). The oil has μ = 0.03 Pa·s.

  • Surface speed: U = π × 0.1 × 25 = 7.854 m/s
  • Shear stress: τ = 0.03 × 7.854 ÷ 0.00005 = 4712 Pa
  • Friction force: F = 4712 × π × 0.1 × 0.08 = 118.4 N
  • Friction torque: T = 118.4 × 0.05 = 5.92 N·m
  • Power lost: P = 2π × 25 × 5.92 = 930 W

The 930 W appears as heat in the oil film, which must be carried away by the oil flow and the bearing housing. Maintenance relies on this: if the viscosity falls because the oil is too hot, the film thins and metal contact can follow. If the viscosity is too high, the bearing runs hot from the extra resistance. The oil is checked for the right grade, for contamination and for temperature, and the bearing clearance is checked against wear limits.

8.1.7 Viscous Resistance of Foot-step Bearings

A foot-step bearing, also called a pivot bearing, carries the axial load at the lower end of a vertical shaft. The flat end of the shaft, of radius R, rotates at angular speed ω over a flat bearing plate, with an oil film of thickness h between them.

At radius r the film surface moves at u = ω × r. The shear stress is τ = μ × ω × r ÷ h. Taking a ring of radius r and width dr, the area is 2πr dr, the friction force is τ × 2πr dr and the torque is r times this:

dT = 2π × μ × ω × r³ ÷ h × dr

Integrating from 0 to R:

T = π × μ × ω × R⁴ ÷ (2h)

and the power lost is P = T × ω = π × μ × ω² × R⁴ ÷ (2h).

The torque depends on the fourth power of the radius, so a larger end diameter brings a much higher resistance, and it falls as the film gets thicker.

Worked example: a shaft with an end radius of 50 mm turns at 300 rev/min (ω = 31.42 rad/s) over an oil film of 0.2 mm, with μ = 0.05 Pa·s.

  • Torque: T = π × 0.05 × 31.42 × 0.05⁴ ÷ (2 × 0.0002) = π × 0.05 × 31.42 × 6.25 × 10⁻⁶ ÷ 0.0004 = 0.0771 N·m
  • Power lost: P = 0.0771 × 31.42 = 2.42 W

The heat produced is carried off by the oil. For inspection, signs of excess resistance are a rise in the temperature of the bearing, motor current that rises at the same speed, and noise or vibration. Oil that is too thin allows the end of the shaft to touch the plate, and oil that is dirty increases wear. The bearing is serviced on the basis of the oil temperature and condition.

8.1.8 Viscous Resistance of Collar Bearings

A collar bearing carries an axial load on a collar fixed to a shaft, which is a flat ring surface with an inner radius R₁ and an outer radius R₂ running against a flat plate, with an oil film of thickness h. The shaft passes through the middle, so there is no oil film within the radius R₁. The analysis is the same as for the foot-step bearing, but the integration runs from R₁ to R₂:

T = π × μ × ω × (R₂⁴ − R₁⁴) ÷ (2h)

and the power lost is P = T × ω.

When the shaft carries several collars, each collar adds a torque of this size, so the total is the number of collars multiplied by T.

Worked example: the shaft in the previous example has a collar with R₂ = 60 mm and R₁ = 30 mm, with the same film of 0.2 mm, speed of 300 rev/min (ω = 31.42 rad/s) and μ = 0.05 Pa·s.

  • R₂⁴ − R₁⁴ = 0.06⁴ − 0.03⁴ = 1.296 × 10⁻⁵ − 0.081 × 10⁻⁵ = 1.215 × 10⁻⁵ m⁴
  • Torque: T = π × 0.05 × 31.42 × 1.215 × 10⁻⁵ ÷ (2 × 0.0002) = 0.1499 N·m
  • Power lost: P = 0.1499 × 31.42 = 4.71 W

The collar loses nearly twice as much power as the foot-step end of 50 mm radius, because its outer radius is larger. The resistance can be reduced by making the outer radius smaller, by using a thicker film or a thinner oil, or by running the bearing slower. The measures against too much resistance are the same as for the other bearings: keep the oil at the right viscosity and temperature, keep it clean, and watch the bearing temperature and power draw.

Practice Questions

  1. Explain how the velocity distribution in laminar flow through a circular pipe affects pressure loss in a fluid transport system. (10 marks)

  2. Describe the factors influencing viscous resistance in journal bearings and how they impact machine performance. (10 marks)

  3. Calculate the power absorbed in viscous flow given a lubricant viscosity of 0.1 Pa·s, a velocity gradient of 50 s⁻¹, and a flow area of 0.02 m². (Show all steps) (10 marks)

  4. Discuss the practical considerations for maintaining foot-step bearings in heavy machinery to minimize viscous resistance related problems. (10 marks)

  5. Compare the flow characteristics of viscous fluids through circular pipes and annuli, highlighting their implications for mechanical production technicians. (10 marks)

Chapter Summary

This chapter explored the behavior of viscous fluids flowing through various configurations, beginning with the flow of viscous fluid in circular pipes, where velocity profiles and pressure drops were examined. The discussion extended to viscous flow through an annulus, highlighting the complexities introduced by concentric cylindrical boundaries. Flow between two parallel plates was analyzed under different conditions, including one plate at rest, both plates stationary, and both plates moving in opposite directions, each affecting the fluid velocity distribution uniquely. The concept of kinetic energy momentum was introduced to understand the energy changes within viscous flows. Calculations of power absorbed in viscous flow provided insight into the energy losses due to fluid friction. The chapter also addressed viscous resistance in mechanical components such as journal bearings, foot-step bearings, and collar bearings, emphasizing how viscous forces impact their performance and efficiency. Overall, the chapter integrated theoretical principles with practical applications to deepen understanding of viscous fluid flow in engineering systems.

Self-Assessment

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A. Written Assessment

  1. What is the primary difference between laminar and turbulent viscous flow in circular pipes? (2 marks)
  2. Explain how the velocity profile of viscous fluid flow between two parallel plates changes when one plate moves and the other is stationary. (3 marks)
  3. Calculate the power absorbed in viscous flow if the shear stress and velocity gradient are known. (3 marks)
  4. Describe the role of viscous resistance in journal bearings and how it affects mechanical performance. (3 marks)
  5. Identify the effect of an annulus geometry on viscous fluid flow compared to flow in a single circular pipe. (2 marks)
  6. What is the significance of kinetic energy momentum in analyzing viscous flow systems? (2 marks)
  7. Give two practical applications of viscous resistance in collar bearings within mechanical production. (2 marks)
  8. Outline the steps to determine viscous resistance in foot-step bearings. (3 marks)
  9. How does the movement of both parallel plates in opposite directions influence the viscous flow characteristics? (3 marks)
  10. Discuss why viscous flow considerations are critical in the design of fluid transport systems in Kenyan manufacturing plants. (3 marks)
Show Answers
  1. Laminar flow is characterized by smooth, orderly fluid motion with parallel layers, while turbulent flow involves chaotic fluctuations and mixing. Laminar flow occurs at low Reynolds numbers and is dominated by viscous forces.
  2. When one plate moves and the other is stationary, the velocity profile between the plates becomes linear, with velocity increasing from zero at the stationary plate to the velocity of the moving plate, creating a shear flow.
  3. Power absorbed in viscous flow is calculated by integrating the product of shear stress and velocity gradient across the flow area; it represents the energy dissipated due to fluid viscosity.
  4. Viscous resistance in journal bearings creates a lubricating film that supports loads and reduces metal-to-metal contact, thereby improving bearing life and reducing frictional losses.
  5. The annulus geometry introduces an additional flow path and changes the velocity distribution, often increasing flow resistance compared to a single pipe due to the smaller effective flow area and shear effects on both walls.
  6. Kinetic energy momentum accounts for the energy carried by fluid motion; it is essential for understanding flow behavior, pressure changes, and forces on boundaries in viscous flow systems.
  7. Collar bearings use viscous resistance to support radial loads and reduce wear; they are common in rotating machinery like milling machines and lathes in workshops.
  8. To determine viscous resistance in foot-step bearings: measure bearing dimensions, calculate fluid film thickness, determine viscosity, compute shear forces, and finally calculate resistance based on velocity gradients.
  9. When both plates move in opposite directions, the velocity profile is linear but symmetric about the midpoint, increasing shear rates and energy dissipation compared to single moving plate scenarios.
  10. Viscous flow affects pump sizing, pipe selection, and energy efficiency; in Kenyan manufacturing plants such as those in Athi River industrial area, accounting for viscous losses ensures reliable fluid transport and cost-effective operation.

B. Oral Assessment

  1. Explain how knowledge of viscous flow between parallel plates can be applied to improve lubrication systems in mechanical production equipment used in Kenyan workshops.
  2. Discuss the challenges and considerations in measuring viscous resistance in journal bearings during maintenance at a county government vehicle repair workshop.
Answer Guide

Question 1 key points:

  • Understanding velocity profiles in viscous flow helps optimize lubricant film thickness to reduce wear and friction.
  • Proper selection of lubricant viscosity and flow conditions enhances equipment longevity and efficiency in workshop machines like milling machines and presses.

Question 2 key points:

  • Accurate measurement requires understanding fluid properties and bearing geometry under operating conditions.
  • Challenges include variability in lubricant viscosity due to temperature, contamination, and difficulty accessing bearings for direct measurement.
  • Regular monitoring and use of indirect indicators like temperature rise and vibration help assess viscous resistance effects.

C. Case Study

At a medium-sized textile manufacturing plant in Eldoret, the maintenance team is tasked with optimizing the lubrication system of the spinning machines, focusing on journal and collar bearings to reduce downtime caused by bearing failures.

Tasks:
a) Analyze how viscous resistance in journal bearings affects machine performance and maintenance intervals. (5 marks)
b) Propose a method to measure and monitor viscous resistance in the collar bearings used in the spinning machines. (5 marks)
c) Recommend practical steps to optimize viscous flow conditions in the lubrication system to improve overall machine reliability. (5 marks)

Suggested Approach

a) Discuss how viscous resistance creates a lubricating film that supports load and reduces metal contact, which prevents wear and overheating. Emphasize the impact on machine uptime and the cost implications of poor lubrication at the Eldoret plant.

b) Suggest using indirect methods such as temperature sensors and vibration analysis alongside lubricant viscosity tests. Outline the procedure to measure lubricant viscosity, bearing dimensions, and operating speeds to estimate viscous resistance.

c) Recommend controlling lubricant temperature to maintain optimal viscosity, scheduling regular lubricant replacement to prevent contamination, and adjusting bearing clearances to maintain appropriate film thickness. Highlight the role of staff training on lubrication best practices to sustain improvements.

Chapter Examination Questions

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SECTION A (40 Marks) - Answer ALL Questions

  1. Explain the characteristics of viscous flow in circular pipes and how they influence fluid transport in a milk processing plant. (4 marks)
  2. Derive the velocity distribution equation for viscous fluid flowing through an annulus and state the assumptions involved. (4 marks)
  3. Compare the flow of viscous fluid between two parallel plates when one plate is moving and the other is at rest. (4 marks)
  4. Describe the effect of kinetic energy momentum in viscous flow and its relevance in pump design at a Nairobi water treatment facility. (4 marks)
  5. Calculate the power absorbed in viscous flow given a fluid viscosity, pipe dimensions, and flow velocity in a cooling system. (4 marks)
  6. Outline the factors affecting viscous resistance in journal bearings used in a maize milling machine. (4 marks)
  7. Discuss the role of viscous resistance in foot-step bearings and how it impacts the performance of an electric motor in a hotel laundry system. (4 marks)
  8. Explain the viscous resistance of collar bearings and its significance in maintaining the efficiency of an elevator system in a Nairobi commercial building. (4 marks)
  9. State the boundary conditions applied when analyzing viscous flow between two stationary parallel plates. (4 marks)
  10. Identify the practical challenges faced in measuring viscous flow parameters in industrial pipe networks at a county government water supply department. (4 marks)
Section A - Answers
  1. Viscous flow in circular pipes is characterized by laminar or turbulent flow regimes, with velocity gradients causing shear stress. In milk processing plants, understanding this helps in designing pipes that minimize energy loss and contamination.
  2. The velocity distribution equation for annular flow assumes steady, incompressible, laminar flow with no-slip conditions at the boundaries. The flow profile is derived from the Navier-Stokes equations in cylindrical coordinates.
  3. When one plate moves and the other is stationary, a linear velocity profile develops due to viscous shear, known as Couette flow, differing from stationary plates where flow is driven by pressure gradient only.
  4. Kinetic energy momentum affects fluid velocity changes and pressure distribution; in pump design, this ensures efficient energy transfer and prevents cavitation in water treatment plants.
  5. Power absorbed is calculated using the formula involving viscosity, velocity gradient, and pipe dimensions, representing energy lost to overcome viscous forces in the cooling system.
  6. Viscous resistance in journal bearings depends on lubricant viscosity, bearing clearance, rotational speed, load, and temperature, affecting friction and wear in milling machines.
  7. Foot-step bearings experience viscous resistance that dampens vibration and supports axial loads; in laundry systems, this ensures smooth motor operation and longevity.
  8. Collar bearings’ viscous resistance arises from lubricant film shear; it is critical in elevators to reduce friction, ensuring safe and efficient vertical movement.
  9. Boundary conditions include no-slip at both plates (velocity zero at surfaces), ensuring velocity gradients develop within the fluid layer.
  10. Challenges include turbulence, pipe roughness, temperature variations, and sensor placement, complicating accurate measurement of flow parameters in water supply networks.

SECTION B (60 Marks) - Answer any TWO Questions

Question 11 (Compulsory - 20 marks)
At Kenyatta National Hospital’s mechanical workshop, a new cooling system uses viscous oil flowing through circular pipes and journal bearings to support rotating equipment.
a) Analyze how viscous flow characteristics in circular pipes affect the cooling efficiency and suggest design considerations to optimize flow. (10 marks)
b) Evaluate the impact of viscous resistance in journal bearings on the operational reliability of the rotating equipment and propose maintenance strategies. (10 marks)

Question 12 (20 marks)
Derive the expression for velocity distribution and shear stress for viscous fluid flow between two parallel plates where both plates move in opposite directions, and discuss practical applications of this flow in mechanical systems.

Question 13 (20 marks)
Explain the concept of kinetic energy momentum in viscous flow and calculate the power absorbed by a viscous fluid flowing through a pipe with given dimensions and flow velocity. Include the importance of these calculations in designing fluid transport systems in a county government water department.

Question 14 (20 marks)
Discuss the viscous resistance encountered in collar bearings and foot-step bearings, highlighting how these resistances influence the design and performance of mechanical components in a hotel’s elevator and laundry services.

Section B - Answers

Question 11
a) Viscous flow in circular pipes causes velocity gradients that induce shear stress, leading to pressure drops which affect cooling efficiency. Optimizing pipe diameter, surface finish, and flow velocity can reduce energy losses. At Kenyatta National Hospital, designing pipes with appropriate diameters and smooth interiors ensures effective heat transfer and reduces pumping costs.
b) Viscous resistance in journal bearings arises from lubricant shear forces, affecting friction and heat generation. This resistance influences equipment reliability by potentially causing wear or seizure. Regular lubrication checks, temperature monitoring, and ensuring correct bearing clearances extend equipment life.

Question 12
The velocity distribution for flow between two plates moving oppositely is derived from solving the Navier-Stokes equations with boundary conditions of respective plate velocities. The resulting linear velocity profile and corresponding shear stress are critical for designing conveyor belts and sliding machinery parts where relative motion occurs.

Question 13
Kinetic energy momentum represents the fluid’s energy due to motion, affecting pressure and flow behavior. Power absorbed by viscous flow is computed using the shear stress and velocity gradient, typically by integrating the viscous force over the flow volume. In county water departments, these calculations help size pumps and pipes to ensure efficient water delivery with minimal energy waste.

Question 14
Viscous resistance in collar bearings arises from the lubricant film shearing between the collar and shaft, while foot-step bearings experience resistance from axial load lubrication. These resistances reduce mechanical wear but introduce frictional losses, influencing bearing design to balance load capacity and efficiency. In hotels, proper bearing design ensures smooth elevator operation and reliable laundry machinery performance.

References

  1. TVET CDACC - Thermodynamics And Fluid Mechanics Principles Curriculum (Cycle 3, 2025)
  2. TVET CDACC - Thermodynamics And Fluid Mechanics Principles Occupational Standards

Chapter Practical Activities

Practical 1: Determining Viscous Flow Characteristics in Circular Pipes

Time: 2 Hours | Type: Individual

Resources Required:

  • Hydraulic bench with adjustable flow rate and pressure gauge
  • Transparent circular pipe section (50 mm diameter, 2 m length)
  • Stopwatch
  • Manometer
  • Measuring tape
  • Water or light oil as test fluid
  • PPE: Overall, safety boots, gloves

At a Machakos County water treatment plant training centre, mechanical production technicians often need to analyze fluid flow in pipes to ensure efficient system design and maintenance.

Tasks:
i. Set up the hydraulic bench and connect the circular pipe section securely.
ii. Measure and record the volumetric flow rate and pressure drop along the pipe at different flow velocities.
iii. Calculate the Reynolds number to determine whether the flow is laminar or turbulent.
iv. Plot the velocity profile and discuss the effect of viscosity on flow behaviour.

Assessor Observation Criteria:

  • [ ] Correct and safe setup of hydraulic bench and pipe section
  • [ ] Accurate measurement of flow rate and pressure drop
  • [ ] Correct calculation of Reynolds number and flow regime identification
  • [ ] Clear and logical plotting of velocity profile

Practical 2: Investigating Viscous Flow Through an Annulus

Time: 2 Hours | Type: Individual

Resources Required:

  • Annulus flow test rig with adjustable inner and outer pipe diameters
  • Fluid reservoir with pump (water or oil)
  • Pressure sensors and manometer
  • Stopwatch
  • Vernier caliper
  • PPE: Overall, safety boots, gloves

Technicians at a Nairobi refinery need to understand flow behaviour through annular spaces in heat exchangers and pipelines to optimize performance.

Tasks:
i. Assemble the annulus flow test rig with specified inner and outer pipe dimensions.
ii. Measure pressure drop and flow rate for varying flow velocities.
iii. Calculate flow parameters including velocity distribution and shear stress.
iv. Compare experimental results with theoretical viscous flow equations for annulus.

Assessor Observation Criteria:

  • [ ] Proper assembly and secure connections of annulus rig
  • [ ] Accurate recording of pressure and flow data
  • [ ] Correct application of formulas and calculations
  • [ ] Analytical comparison between measured and theoretical values

Practical 3: Measuring Flow Velocity Between Two Parallel Plates with One Plate Moving

Time: 1.5 Hours | Type: Individual

Resources Required:

  • Parallel plate flow apparatus with one plate motor-driven
  • Flow meter
  • Stopwatch
  • Measuring scale
  • Water or glycerin as test fluid
  • PPE: Overall, safety boots, gloves

In a Kisumu textile factory, understanding fluid flow between moving surfaces is essential for lubrication and cooling system design.

Tasks:
i. Set up the parallel plate apparatus with one plate moving at a set speed.
ii. Measure fluid velocity profile between the plates at different positions.
iii. Calculate shear stress and velocity gradient.
iv. Analyze the effect of plate speed on viscous flow characteristics.

Assessor Observation Criteria:

  • [ ] Safe and correct setup of apparatus
  • [ ] Precise measurement of velocity at multiple points
  • [ ] Accurate calculation of shear stress and gradients
  • [ ] Insightful analysis linking plate velocity to flow behaviour

Practical 4: Observing Viscous Flow Between Two Stationary Parallel Plates

Time: 1 Hour | Type: Pairs

Resources Required:

  • Parallel plate flow rig with both plates fixed
  • Dye injection kit for flow visualization
  • Stopwatch
  • Transparent test fluid (water with tracer particles)
  • PPE: Overall, safety boots, gloves

At a Nairobi Technical Training Institute, students simulate viscous flow in lubrication layers by studying stationary plate configurations.

Tasks:
i. Assemble the rig ensuring both plates are stationary and parallel.
ii. Inject dye into the fluid to visualize flow patterns.
iii. Measure flow velocity and record observations.
iv. Sketch the velocity profile and discuss viscous effects.

Assessor Observation Criteria:

  • [ ] Correct assembly and fluid handling
  • [ ] Effective use of dye to visualize flow
  • [ ] Accurate velocity measurements
  • [ ] Clear and labelled sketches of velocity profile

Practical 5: Analyzing Viscous Flow with Both Plates Moving in Opposite Directions

Time: 2 Hours | Type: Individual

Resources Required:

  • Dual-motor parallel plate flow apparatus
  • Tachometer
  • Stopwatch
  • Flow meter
  • Water or light oil
  • PPE: Overall, safety boots, gloves

At a Kisii dairy processing plant, technicians evaluate flow between moving surfaces to optimize lubricant application in machinery.

Tasks:
i. Configure the apparatus with both plates moving in opposite directions at set speeds.
ii. Measure fluid velocity profiles at different depths.
iii. Calculate velocity gradients and shear stresses.
iv. Discuss how opposing plate motion influences viscous flow.

Assessor Observation Criteria:

  • [ ] Correct synchronization of plate speeds
  • [ ] Accurate velocity and flow measurements
  • [ ] Precise calculations of gradients and stresses
  • [ ] Analytical discussion of flow dynamics

Practical 6: Calculating Kinetic Energy and Momentum in Viscous Fluid Flow

Time: 1.5 Hours | Type: Individual

Resources Required:

  • Flow bench with velocity measurement devices (Pitot tube, manometer)
  • Calculator
  • Measuring tape
  • Water as test fluid
  • PPE: Overall, safety boots, gloves

Mechanical technicians at a Mombasa port logistics company assess fluid momentum to improve hydraulic system efficiency.

Tasks:
i. Measure fluid velocity and pressure at two points along a pipe.
ii. Calculate kinetic energy per unit volume and momentum flow rate.
iii. Analyze the impact of viscous forces on energy loss.
iv. Prepare a report summarizing findings and implications.

Assessor Observation Criteria:

  • [ ] Accurate measurement of velocity and pressure
  • [ ] Correct application of kinetic energy and momentum formulas
  • [ ] Clear explanation of viscous effects on energy
  • [ ] Well-structured and concise report

Practical 7: Measuring Power Absorbed in Viscous Flow Systems

Time: 2 Hours | Type: Individual

Resources Required:

  • Hydraulic test rig with torque and speed sensors
  • Dynamometer
  • Stopwatch
  • Fluid reservoir with adjustable flow
  • PPE: Overall, safety boots, gloves, eye protection

At a Nakuru manufacturing plant, technicians measure power losses due to viscous flow in hydraulic motors for maintenance planning.

Tasks:
i. Set up the hydraulic rig and connect torque and speed sensors.
ii. Record torque and rotational speed at different flow rates.
iii. Calculate power absorbed due to viscous effects.
iv. Compare measured power with theoretical predictions.

Assessor Observation Criteria:

  • [ ] Safe setup and sensor calibration
  • [ ] Accurate recording of torque and speed data
  • [ ] Correct power calculations
  • [ ] Analytical comparison between data and theory

Practical 8: Determining Viscous Resistance of a Journal Bearing

Time: 2.5 Hours | Type: Individual

Resources Required:

  • Journal bearing test rig with load application
  • Torque sensor
  • Tachometer
  • Stopwatch
  • Lubricating oil
  • PPE: Overall, safety boots, gloves

At a Thika manufacturing workshop, mechanical production technicians evaluate bearing resistance to predict machine performance and lifespan.

Tasks:
i. Install the journal bearing on the test rig and apply specified load.
ii. Measure torque required to rotate the shaft at various speeds.
iii. Calculate viscous resistance and friction coefficient.
iv. Discuss the influence of lubricant viscosity on bearing performance.

Assessor Observation Criteria:

  • [ ] Proper installation and load application
  • [ ] Precise torque and speed measurements
  • [ ] Accurate viscous resistance calculations
  • [ ] Insightful discussion on lubricant effects

Practical 9: Evaluating Viscous Resistance of a Foot-step Bearing

Time: 2 Hours | Type: Individual

Resources Required:

  • Foot-step bearing test setup
  • Torque and speed measuring devices
  • Lubricant supply
  • Stopwatch
  • PPE: Overall, safety boots, gloves

Technicians at a Kisumu power plant perform tests on foot-step bearings to ensure reliability under heavy loads.

Tasks:
i. Mount the foot-step bearing on the test apparatus.
ii. Measure torque and speed at different lubricant viscosities.
iii. Calculate viscous resistance and relate to bearing design.
iv. Prepare a technical note on maintenance recommendations.

Assessor Observation Criteria:

  • [ ] Correct mounting and lubrication
  • [ ] Accurate measurement recording
  • [ ] Proper calculations relating to viscous resistance
  • [ ] Clear and practical maintenance recommendations

Practical 10: Measuring Viscous Resistance of a Collar Bearing

Time: 1.5 Hours | Type: Individual

Resources Required:

  • Collar bearing rig with adjustable speed control
  • Torque sensor
  • Stopwatch
  • Lubricating oil
  • PPE: Overall, safety boots, gloves

At a Nairobi hotel’s maintenance workshop, technicians assess collar bearing resistance to troubleshoot noisy machinery.

Tasks:
i. Set up the collar bearing on the test rig.
ii. Measure torque at various rotational speeds.
iii. Calculate viscous resistance and analyze lubrication effectiveness.
iv. Suggest improvements for bearing operation based on results.

Assessor Observation Criteria:

  • [ ] Safe and correct setup
  • [ ] Accurate torque and speed measurements
  • [ ] Correct viscous resistance computations
  • [ ] Practical and relevant improvement suggestions

Practical 11: Sketching and Calculating Velocity Profiles for Viscous Flow in Pipes

Time: 1 Hour | Type: Individual

Resources Required:

  • Pipe flow experiment setup with manometer taps
  • Ruler and graph paper
  • Stopwatch
  • PPE: Overall, safety boots

In a Kisumu county hospital engineering department, technicians use velocity profiles to diagnose flow issues in medical gas delivery pipes.

Tasks:
i. Measure pressure at multiple points along the pipe radius.
ii. Calculate velocity at each point using pressure data.
iii. Sketch the velocity profile across the pipe diameter.
iv. Explain the influence of viscosity on the profile shape.

Assessor Observation Criteria:

  • [ ] Accurate pressure measurement and data recording
  • [ ] Correct velocity calculations
  • [ ] Precise and labelled velocity profile sketch
  • [ ] Clear explanation of viscous effects

Practical 12: Computer Simulation of Viscous Fluid Flow Between Plates

Time: 2 Hours | Type: Individual

Resources Required:

  • Computer with fluid dynamics simulation software (e.g., ANSYS Fluent, OpenFOAM)
  • Sample data sets for fluid properties
  • PPE: None required (computer room setting)

At the Technical University of Kenya, mechanical production students use simulation software to predict flow behaviour in manufacturing processes.

Tasks:
i. Set up a simulation model of viscous fluid flow between two parallel plates.
ii. Input fluid properties and plate velocities as per given parameters.
iii. Run the simulation and extract velocity and shear stress data.
iv. Compare simulation results with theoretical calculations.

Assessor Observation Criteria:

  • [ ] Correct model setup and input of parameters
  • [ ] Successful simulation execution
  • [ ] Accurate data extraction and interpretation
  • [ ] Sound comparison and explanation of results
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