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Research Papers: Gas Turbines: Combustion, Fuels, and Emissions

Conrod Bearings With an Optimized Narrow Circumferential Oil Groove: Simulated Durability Improvement for Heavy-Duty Applications

[+] Author and Article Information
Konstantinos Kalogiannis

MAHLE Engine Systems UK Ltd.,
2 Central Park Drive,
Rugby CV23 0WE, UK
e-mail: konstantinos.kalogiannis@gb.mahle.com

David R. Merritt

MAHLE Engine Systems UK Ltd.,
2 Central Park Drive,
Rugby CV23 0WE, UK
e-mail: david.merritt@gb.mahle.com

Omar Mian

MAHLE Engine Systems UK Ltd.,
2 Central Park Drive,
Rugby CV23 0WE, UK
e-mail: omar.mian@gb.mahle.com

Hugh Gibson

MAHLE Industries Inc.
One MAHLE Drive,
Morristown, TN 37815-0748
e-mail: hugh.gibson@us.mahle.com

Contributed by the Combustion and Fuels Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received March 2, 2015; final manuscript received March 11, 2015; published online April 8, 2015. Editor: David Wisler.

J. Eng. Gas Turbines Power 137(10), 101510 (Oct 01, 2015) (9 pages) Paper No: GTP-15-1073; doi: 10.1115/1.4030097 History: Received March 02, 2015; Revised March 11, 2015; Online April 08, 2015

Under normal operating conditions, engine crankshaft bearings experience variations in oil film temperature due to shearing of the oil film. This can have a negative impact on the bearing operating life since the viscosity of the lubricant is temperature dependent. In the current study, a thermo-elastohydrodynamic lubrication (TEHL) analysis has been conducted using an in-house specialized simulation package called (software for analysis of bearings in reciprocating engines) SABRE-TEHL. This advanced simulation tool has been used to optimize a new bearing design feature leading to a significant temperature reduction, which in turn increases the robustness of the system.

Copyright © 2015 by ASME
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References

Xu, H., 1996, “Elastohydrodynamic Lubrication in Plain Bearings,” 23rd Leeds-Lyon Symposium on Tribology, Leeds, UK, Sept. 10–13, pp. 641–650. [CrossRef]
Xu, H., 1996, “Effects of EHD Contacts Upon the Bearing and Housing Behaviour,” SAE Technical Paper No. 960987. [CrossRef]
Mian, O., and Jones, G. J., 1995, “An Improved Technique for the Estimation of Crankshaft Bearing Temperatures,” IMechE Autotech '95, Birmingham, UK, Nov. 7–9, Report No. C498/2039/213.
Merritt, D., Haxha, V., Mian, O., and Ferrayra, S., 2013, “Crankshaft Bearings Oil Flow Prediction Tools Including CFD,” 13th Stuttgart International Symposium: Automotive and Engine Technology, Stuttgart, Feb. 26–27, pp. 565–588.
Wang, D., Jones, G., Mian, O., Merritt, D., and Simon, T., 2007, “Oil Flow and Temperature Predictions for a Big-End Bearing,” ASME Paper No. IJTC2007-44198. [CrossRef]
Wang, D., Parker, D., and Williams, B., 2000, “Correlation of Measured and Predicted Oil Flow for a Big-End Bearing,” SAE Technical Paper No. 2000-01-2919. [CrossRef]
Wang, D., 1999, “Development and Validation of Finite Difference SABRE-EHL Code,” GVRR Technical Report No. 1046.
Mian, O., Merritt, D., and Wang, D., 2002, “The Effect of Crankshaft Flexibility on EHL of Connecting Rod Bearings,” SAE Technical Paper No. 2002-01-0295. [CrossRef]
Merritt, D., Mian, O., and Wang, D., 2007, “Connecting Rod Bearing EHL Analysis Including Inertia Effects Due to Distributed Rod Mass,” SAE Technical Paper No. 2007-24-0134. [CrossRef]
Merritt, D., 2013, “The Use of Abaqus in an Engine Bearing Design Environment,” Simulia Community Conference, Vienna, May 21–23.
Wang, D., and Parker, D. D., 2004, “Effects of Multi-Order Journal Lobing on the Performance of a Big-End Bearing in a Diesel Engine,” SAE Technical Paper No. 2004-01-3469. [CrossRef]
Wang, D., Mian, O., Merritt, D., Praca, M., and Zhu, G. D., 2008, “Elasto-Hydrodynamic Lubrication Analysis and Wear Prediction for a Connecting Rod Small-End Bush and Piston Interface,” SAE Technical Paper No. 2008-36-0068. [CrossRef]

Figures

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Fig. 1

Analysis work flow for connecting rod bearings

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Fig. 2

Connecting rod and bearing geometry

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Fig. 3

Crankshaft geometry

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Fig. 4

Bearing bore deformation extracted from FEA

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Fig. 5

FEA clearance fitted shape including bearing features

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Fig. 6

Polar load diagram for 1447 rpm

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Fig. 7

Polar load diagram for 2045 rpm

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Fig. 8

Oil groove configurations

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Fig. 9

Oil film temperature history maps

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Fig. 10

Instantaneous oil flows for various groove depths

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Fig. 11

Inertia oil pressure variations

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Fig. 12

Effect of oil groove on peak oil film pressure at maximum torque condition

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Fig. 13

Effect of oil groove on minimum oil film thickness at maximum torque condition

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Fig. 14

Journal temperature at maximum speed condition

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Fig. 15

Cycle-averaged oil flow at maximum speed condition

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Fig. 16

Oil flow and temperature change for reduced clearances relative to standard clearance

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Fig. 17

Wear volume and wear depth for reduced clearances relative to standard clearance

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