Predicting friction reliably and accurately in journal bearings—A systematic validation of simulation results with experimental measurements

It is the aim of this work to predict friction in journal bearings reliably and accurately under realistic dynamic working conditions. To this purpose elastohydrodynamic (EHD) calculations using an extensive oil-model and including an approach to the conformal roughnesses of the bearing surfaces are carried out for transient loads typical for current utility vehicles (40 MPa) as well as for considerably higher specific loads (70 MPa) and for different lubricants (SAE10, SAE20, SAE30 and SAE40) to account for a large span of working conditions ranging from full film lubrication to mixed lubrication with metal–metal contact.The results obtained from this simulation model are compared to measurements performed on a journal bearing test rig. We find that the results of the presented approach agree very closely with the experimental values. The presented approach allows consequently to investigate the effectiveness of changes in bearing geometry, bearing materials, bearing surface roughness, lubricant viscosity and engine operating conditions to reduce friction in journal bearings.

► A simulation approach is proposed to predict friction in journal bearings.
► The method covers full film and mixed lubrication.
► Validation is carried out with a large set of measurements conducted on a test rig.
► The results from the presented model agree closely with the experimental data.
► The potential for friction reduction by choosing the optimum lubricant is discussed.