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.

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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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