A Design for High-Speed Journal Bearings with Reduced Pad Size and Improved Efficiency

Abstract

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.

Friction and Lubrication of Sliding Bearings

“…This approach offers a tool that may be used to look inside bearings and provide further knowledge of the structure and lubrication design of ball bearings. Hagemann et al [7] investigated a two-lobe offset-halves type of bearing specially designed to reduce frictional power loss. In this design, part of the bearing sliding surface is substituted with free areas to provide negligible friction in its boundary layers, resulting in a 37.2% improvement of frictional power loss for the test bearing.…”