Tribological failure analysis of journal bearings used in sugar mills

In present paper the premature failure of journal bearings encountered in sugar mills has been analyzed. The causes of bearing failure are identified by simulating the operating conditions and conducting controlled experiments on a fully automated Journal Bearing Test Rig with provisions for varied combination (i.e. load, speed, and lubricating oil) of operating conditions. The results of performance behavior (i.e. coefficient of friction, change in surface roughness and weight loss) of the bearings as observed in these experiments have been reported. The theoretical and experimental results indicate the existence of boundary lubrication conditions in sugar mill journal bearings. To mitigate the problem of relatively high wear, lubricating oil with boundary additives have been tried and results are reported.

► Sugar mill journal bearing failure identified by simulation and controlled testing.
► Premature failure due to existence of boundary/mixed lubrication conditions.
► Using EP additives significantly reduce friction and bearing weight loss.
► Tested bearings with radial clearance ranging from 0.075% to 0.17% of bearing radius.
► Low friction and wear observed for radial clearance of 0.1–0.15% of bearing radius.