Peder Klit

Improvement of journal bearing operation at heavy misalignment using bearing flexibility and compliant liners

A flexure journal bearing design is proposed that will improve operational behaviour of a journal bearing at pronounced misalignment. Using a thermoelastohydrodynamic model, it is shown that the proposed flexure journal bearing has vastly increased the hydrodynamic performance compared to the stiff bearing when misaligned. The hydrodynamic performance is evaluated on lubricant film thickness, pressure and temperature. Furthermore, the influence of a compliant bearing liner is investigated and it is found that it increases the hydrodynamic performance when applied to a stiff bearing, whereas the liner has practically no influence on the flexure journal bearings performance.

Coefficient of Friction Measurements for Thermoplastics and Fibre Composites Under Low Sliding Velocity and High Pressure

Friction materials for typical brake applications are normally designed considering thermal stability as the major performance criterion. There are, however, brake applications with very limited sliding velocities, where the generated heat is insignificant. In such cases it is possible that friction materials which are untypical for brake applications, like thermoplastics and fibre composites, can offer superior performance in terms of braking torque, wear resistance and cost than typical brake linings. In this paper coefficient of friction measurements for various thermoplastic and fibre composite materials running against a steel surface are presented. All tests were carried out on a pin-on-disc test-rig in reciprocating operation at a fixed sliding speed and various pressure levels for both dry and grease lubricated conditions. Moreover, a generic theoretical framework is introduced in order to interpret the changes of friction observed during the running-in phase.

Development of a model capable of predicting the performance of piston ring—cylinder liner-like tribological interfaces

Abstract Friction in the piston ring package (piston, piston rings, and liner) is a major source of power consumption in large two-stroke marine diesel engines. In order to improve the frictional and wear performance, knowledge about the tribological interface between piston rings and liner is needed. The work described in this article addresses the subject from both an experimental and a theoretical perspective. First, a one-dimensional numerical model based on the Reynolds equation is presented. It uses a pressure—density relation for the modelling of cavitation. The viscosity is assumed to depend on a measured temperature only; thus, it is not necessary to include the energy equation. Conservation of oil is ensured throughout the domain by considering the amount of oil outside the lubricated interface. A model for hard contact through asperities is also included. Second, a laboratory-scale test rig is described. Results from a number of experimental tests with different geometries and running speeds are presented. Finally, a comparison between the measured friction force and simulated values is given. Good correlation between the measurements and the simulations has been observed, especially when running at a high speed. This article represents the first steps in the pursuit of being able to accurately model the interface between a piston ring and the cylinder liner in large two-stroke diesel engines.

Geometrical design parameters for journal bearings with flexure pads and compliant liners

A hydrodynamic journal bearing utilizing flexure pads with a compliant liner is studied and its performance enhanced through a parametric study. The main geometrical dimensions are varied and the affect on pad performance is analyzed. This will put more knowledge into the design and function of flexure pads. Guidelines are given to the design of the pads and are also covering the polymer liner. It is found that the use of flexure pads is an attractive alternative to pivoted pads. Pivot contact-related failure modes are eliminated and load capacity is not restricted by the force that can be transferred through the pivot contact. When combined with a polymer liner, the pad performance is enhanced further, especially when operating at thin lubricant films.

Experimental Piston Ring Tribology for Marine Diesel Engines

A very important condition for describing the frictional behavior of a piston ring correctly is knowledge about the amount of lubricant present. It is often assumed that piston rings operate under fully flooded conditions, but this is not the case in real life operation. In large two-stroke engines the cylinder oil is supplied periodically to the bearing at discrete locations on the cylinder liner. The shifting in lubrication regimes and the non-uniform oil distribution opens for the possibility of starved conditions for the piston ring bearing. Therefore it is important to measure the oil distribution on the liner as a function of the operating conditions. The amount of lubricant available is reflected in the friction absorbed in the bearing. The paper describes an investigation of the tribological condition between a piston ring and cylinder. A test apparatus is used to study the interaction between a piston ring and a cylinder liner.Copyright

Lubricant transport across the piston ring with flat and triangular lubrication injection profiles on the liner in large two-stroke marine diesel engines

A theoretical investigation of the lubricant transport across the top compression piston ring in a large two-stroke marine diesel engine is presented. A numerical model for solving Reynolds equation between the piston ring and cylinder liner based on the finite difference method in one dimension has been made. The model includes force equilibrium of the piston ring, perturbation of Reynolds equation, and transient mass conservation. The model represents a new method of achieving mass conservation across the piston ring and between different time-dependent positions. For analyzing the lubricant transport across the piston ring, two different kinds of initial lubricant profile on the liner and two different kinds of load are investigated i.e. a flat profile and an approximated triangular profile as well as no load and a combustion load based on a combustion pressure profile. The impact from the different load conditions and different lubricant profiles on the liner are presented for film thicknesses, development in the lubricant profiles on the liner as well as the lubricant consumption at each stroke.

Investigation of different piston ring curvatures on lubricant transport along cylinder liner in large two-stroke marine diesel engines:

A theoretical investigation of the hydrodynamic lubrication of the top compression piston ring in a large two-stroke marine diesel engine is presented. The groove mounted piston ring is driven by the reciprocal motion of the piston. The ring shape follows a circular geometry and the effect of changes in radii is analysed. A numerical model based on the finite difference method in 1D has been developed for solving Reynolds equation in combination with the load equilibrium equation together with flow continuity between the piston ring surface and liner for analysis of the lubricant transport. The cyclic variation throughout one stroke is presented for the minimum film thicknesses at different interesting locations of the piston ring surface together with the friction and the pressure distribution history. The aforementioned parameters have been investigated numerically. The numerical results are presented and discussed.

Testing of bearing materials for large two-stroke marine diesel engines

In large two-stroke marine diesel engines, bearings are designed to last the lifetime of the engine. The design has shown very good service experiences. The design parameters of the main bearings are, among others, based on the average maximum specific load which the bearing should operate under. In general, the frictional loss is less than 1% of the nominal power of the engine but is still a target for optimization. Fatigue mechanisms of bearing lining material are not fully understood and the design limits with regards to minimum oil film thickness, max oil film pressure and oil film pressure gradient are not established. Large two-stroke journal bearings are not suitable for fatigue test due to the size, the low rotational speed and the complexity of such a test-rig. The disc fatigue test rig was designed with the purpose to test white metal coatings under realistic bearing conditions, in a confined time-frame. The test-rig simulates a scale model of a thrust bearing, in contrary to standard design, the bearing lining material is applied to the rotating collar. Parameters, such as bearing load, rotational speed, oil temperature, oil contamination is controlled/monitored in order to achieve repeatability and a systematic approach to the experiments. Test performed on the test-rig shows good correlation on the fatigue cracks with those experienced on large two-stroke journal bearings.

Analysis of bearing steel exposed to rolling contact fatigue

The objective of this work is to characterize fatigue damage in roller bearings under conditions of high load and slippage. A test rig constructed for rolling contact fatigue tests of rings is described, and test results are presented for rings taken from two spherical roller bearings. The preparation of the rings and the loading situation are explained. Test conditions are chosen with the aim of achieving pitting formation at the contacting surfaces. During testing the contact pressure, torque and the rotational speed are monitored and recorded. After testing the tested rings have been characterized using X-ray tomography and scanning electron microscopy. The observations confirm that rolling contact fatigue testing at high loads leads to pitting failure at the contacting surfaces. The pitting mostly appears on one side of the contact, attributed to a nonuniform contact pressure in the axial direction.

Discontinuity effects in dynamically loaded tilting pad journal bearings

This article describes two discontinuity effects that can occur when modelling radial tilting pad bearings subjected to high dynamic loads. The first effect to be treated is a pressure build-up discontinuity effect. The second effect is a contact-related discontinuity that disappears when a contact force is included in the theoretical model. Methods for avoiding the pressure build-up discontinuity effect are proposed.