This paper presents an optimization algorithm for journal bearing profiles with respect to stiffness and load-carrying capacity and an application example of the same. An analytical approach for finding the optimum is derived. How the optimization procedure works when using numerical calculation tools is briefly explained. The application example is introduced and the expected performance of the optimized bearing profile is compared to the expected performance of state-of-the-art bearing profiles. Finally, the measured bearing performance data is compared to the expected values. The findings indicate the effectiveness of the introduced optimization algorithm.

Improving efficiency is a general task in the design process of high-speed journal bearings. A specific fixed-pad bearing geometry featuring reduced pad length and additional design measures with the intention of reducing frictional power loss is investigated, experimentally and theoretically, for a journal diameter of 500 mm up to surface speeds of 94 m/s and unit loads of 5.0 MPa. To model fluid flow in the bearing outside the lubricant gap, an extension to Elrod’s cavitation algorithm based on assuming the inertia of fluid flow is proposed. Validation of the extended thermo-elasto-hydrodynamic lubrication (TEHL) model shows good agreement between measurement and prediction in wide operating ranges, however, with systematic tendencies of the remaining deviations. Furthermore, measured local pressure and film thickness distributions indicate a complex formation of cavitation with an influence of axial flow that is not covered by pure Couette-flow in the cavitation region. Measured as well as predicted data prove increased bearing efficiency for high rotor speeds. To provide understanding on the impact of the applied design measures improving efficiency, their combination is separated into the individual ones. Reduced axial and peripheral pad length both contribute almost equally to the reduction in power loss and improve its value by 37% compared to the standard design. Finally, further steps to deeper identify the behavior of the bearing are comprehensively discussed.

Despite their superior tribological properties, thick-layer bearing coatings based on polyetheretherketone (PEEK) have up to now not been applied in a very high number of plain bearings for industrial applications. This can at least partly be credited to the high costs and low flexibility associated with the coating process for these materials. At the same time, while thick-layer polytetrafluoroethylene (PTFE) coatings have been successfully applied in industrial plain bearings for around 50 years, thin-layer PTFE coatings today constitute the majority of applications of PTFE in plain bearings. It is therefore reasonable to assume a similar approach for thin-layer PEEK coatings. This article reports the performance of a thin-layer PEEK coating directly applied on a mild steel substrate, with results ranging from first sample test through component tests to application in an actual machine and behavior during realistic operating conditions and induced bearing failure.

Despite great research effort in recent decades, cavitation in hydrodynamic journal bearings is still a not completely understood phenomenon. In particular, it is unclear which proportions of different cavitation types are present in a bearing. Novel experimental results show a clear deviation from the predictions of hydrodynamic lubrication theory. This article presents a new approach for modeling cavitation in hydrodynamic bearings by using computational fluid dynamics with the volume of fluid method and a phase of non-condensable gas in the lubrication oil. The validation of the model is achieved through the simulation of a large Offset-Halves Bearing and a subsequent comparison of the results with various experimental data, including the fractional film content. In the results, cavitation also occurs in the convergent gap due to a pressure drop caused by inertia forces. The findings indicate that the cavitation effects in oil-lubricated hydrodynamic bearings are caused by a special form of gaseous cavitation, designated as pseudo-cavitation. The presented model with non-condensable gas is able to reproduce the observed phenomena excellently.

A common approach to optimising hydrodynamic journal bearings for power loss is to reduce the lubricant supply and direct the oil to specific bearing areas where it is needed to guarantee safe operation. This requires information on the processes in the gap and the surrounding pocket areas for both pre-design and simulation. In this paper, a system consisting of a total of eight cameras is used to determine the void fraction in deep grooves outside the lubricant film. The void fraction in the lubrication gap is determined using a novel method for the evaluation of two proximity measurements. While the variation of the deep groove void fraction is realised by a special oil supply and radially adjustable deep groove elements, the gap void fraction is adjusted by the oil supply in the lube oil pockets at the pad leading edges. On the one hand, the experimental investigations show that the void fraction of the deep groove areas has hardly any influence on the general operating behaviour. On the other hand, the void fraction in the lubrication gap can be measured quantitatively for the first time, and the operating point-dependent gas fractions can be visualised. It is also shown that gaseous cavitation is the main mechanism in partially filled regions of the lubrication gap.