This article describes a calculation model for the simulation of the transient wear characteristics of journal bearings subjected to mixed friction. For predetermined time steps the local wear is calculated for circumference and width. The resulting changes to the gap geometry then flow directly into the further calculation process. The solid contact load ratio and boundary friction ratio in the mixed friction area are calculated on the basis of real rough surfaces. Modifications to the rough surfaces resulting from the running-in process are taken into consideration. In addition the microhydrodynamic effects, elastic deformations of the bearing environment and mass conserving cavitation are also recorded. The calculation model’s potential is demonstrated by means of an unsteady loaded conrod bearing.

The accurate prediction of friction in highly loaded concentrated contacts is one of the most challenging aspects of thermal elastohydrodynamic (TEHD) simulation. The correct modelling of fluid behaviour on the macroscale, in particular non-Newtonian flow behaviour, is an essential prerequisite. For many years, shear-thinning models have been developed and validated with different approaches and controversially discussed. In basic research, model fluids are often used in this context, which have a similar behaviour to practical lubricants. Accompanied by earlier research results, this paper carries out comprehensive investigations on the rheometric behaviour of the model fluid squalane. Based on traction measurements at four different tribometers, an overall parameter optimisation and performance evaluation of three different shear-thinning models is performed using numerical TEHD simulations. In order to additionally validate the theoretical viscosity behaviour, the optimised shear-thinning curves are then compared with comprehensive non-equilibrium molecular dynamics (NEMD) simulations. The key aspect of this paper is the simultaneous consideration of the shear-thinning models in terms of rheometric, experimental, and simulative investigations without changing the parameters. All investigations show that the Eyring model, despite its simplicity, provides the best agreement in both the numerical contact simulation and the NEMD simulations.

The following study presents an in situ sensor system which can measure the temperature change of rolling contacts for heavy duty during fluid as well as mixed friction. This thin-film sensor was optimized with regard to its size, spatial resolution, and wear resistance. Extensive tests were carried out with a two-disk test rig and the data of the temperature change were presented. The results show the complex processes within a rolling contact and the strongly interaction of pressure, friction, and temperature development within the contact zone. Due to the detailed sensor and disk characterization, the data are suitable for comparing calculation methods.

The rheological properties of synovial fluid (SF) are essential for the friction behavior and wear performance of total joint replacements. Standardized in vitro wear tests for endoprosthesis recommend diluted calf serum, which exhibits substantial different rheological properties compared to SF. Therefore, the in vitro test conditions do not mimic the in vivo conditions. SF samples from osteoarthritis knee patients and patients undergoing knee endoprosthesis revision surgery were compared biochemically and rheologically. The flow properties of SF samples were compared to synthetic fluid constituents, such as bovine serum albumin (BSA) and hyaluronic acid (HA). Interestingly, HA was identified as a significant contributor to shear-thinning. Using the acquired data and mathematical modelling, the flow behavior of human SF was modelled reliably by an adapted adjustment of biorelevant fluid components. Friction tests in a hard/soft bearing (ceramic/UHMWPE) demonstrated that, in contrast to serum, the synthetic model fluids generate a more realistic friction condition. The developed model for an SF mimicking lubricant is recommended for in vitro wear tests of endoprostheses. Furthermore, the results highlight that simulator tests should be performed with a modified lubricant considering an addition of HA for clinically relevant lubrication conditions.

False brinelling damage in rolling bearings can lead to reduced component lifetimes and increased noise emissions, adversely affecting machine performance. Therefore, minimizing or avoiding such damage is very important. Environmental or operating conditions that can lead to false brinelling damage often cannot be avoided. Alternatively, such damage can be significantly reduced with suitable lubricants. This study utilized a test method from the research project FVA 540 to examine the impact of the base oil viscosity and NLGI class of greases on false brinelling damage at different temperatures. The results showed a clear dependency between the base oil viscosity of greases and the extent of false brinelling damage. Two different thickeners (lithium hydroxystearate/diurea) and different base oil types (PAO/esters) were investigated for this purpose. The results indicate that temperature had a significant effect on the physical and rheological properties of greases and show the potential for reducing false brinelling damage through the selection of appropriate lubricants. These results provide valuable information to improve the performance and lifetime of rolling bearings in industrial settings.