II Fluid Film Bearing Analysis development history

Reynolds equation (RDE): flow balance, h3, time-varying quantities

h 3 p ( h ) ( h ) + = ui x i t x i 12 x i

p pressure, density viscosity, h gap u average surface velocity

~ 1950 to 1975: analytical solutions and mobility/impedance charts

Gmbel boundary conditions (p>0) Parallel gap in width direction Main Objectives: Forces and journal motion ~ 1975 to 1990: numerical solutions Reynolds boundary conditions (p>0, p=0 and p/=0 at tbd boundary) Nominal bores: offset, lemon, multilobe Grooves, pockets, crowning, waviness Main Objectives: pressure distributions, gap distributions ~ 1990 to today: coupled numerical solutions Mass conserving cavitation (stationary or transient) Thermal deformation, elastic deformation Energy equation, mass forces Oil supply (coupled films) Surface roughness and surface patterns Main Objectives: Oil supply losses, Friction losses and wear

II Fluid Film Bearing Analysis simple models

Long bearing assumption, stationary load
No flow in width direction
H 3 p H =6

Bearing Load, Sommerfeld number

Analytical solution
p() = 6(1
3 2 2

2 2 sin + (sin cos + ) 2 sin 1 cos 0

12 1 + cos0 = 1 cos 0

Short bearing assumption (Ocvirk, 1949), stationary load

Dominant pressure gradient in width direction

Analytical solution

Optimum short bearing solution:

parabolic pressure profile in width direction, 1D numerical solution over circumference
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II Fluid Film Bearing Analysis efficient models

Mobility Method of solution (Booker, 1965), transient solution
Lack of fluid inertia in RDE moving coordinate system (pure squeeze)

Mobility Workflow
1. 2. 3. Transform forces to pure squeeze Determine mobility from lookup table Back-transform journal motion
Major assumptions: constant gap over width constant viscosity, density

Advantages
Exact representation of Reynolds BC on p Only one lookup table, just forces and mobilities, no superposition of pressures

II Fluid Film Bearing Analysis advanced models

Reynolds Differential Equation (RDE)

Numerical Solution
Finite-Element Methods pressure distribution

Reynolds Boundary Conditions

Fluids cannot sustain tension Cavitation and air entrainment variational inequalities (p 0) solved as complementarity Problem (Murty)

Mass Conserving Cavitation on

Hyperbolic equation for density of mixture oil/air is solved using upwinding techniques mass conserving cavitation: mixture density
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II Fluid Film Bearing Analysis rough surfaces

Objectives:
to quantify surface roughness effects on lubrication (pressure, friction) to quantify amount of solid-to-solid contact in mixed friction to provide interpretation to calculated minimum gaps

Challenge:
solution of a multi-scale problem surface roughness short scale (~0.1 mm correlation length) bearing dimensions long scale (~20 mm bearing width)

Solution approach (Patir/Cheng, 1978):

Average effect of roughness on flow (hence pressure) is introduced via flow tensors on the global scale, which are determined on a representative rough surface on the local scale

bearing

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II Fluid Film Bearing Analysis rough surfaces

Flow tensors p, s describe the average effect of surface roughness on flow and thus pressure distribution local fluctuations get lost

Calculation of flow factors Local scale

local gap average gap nominal gap roughness amplitudes elastic deformation

Application of flow tensors Global scale

average surface velocity half shear velocity Combined root mean square roughness
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II Fluid Film Bearing Analysis rough surfaces

Flow tensors are determined
for the individual surface roughness (measured surfaces) for characteristic classes of surfaces stochastic roughness / waviness / structured surfaces

Assessment in simple and basic numerical studies

in the principal axis system (- principal values) solution of Reynolds equation with defined boundary conditions stored in lookup tables for use in average Reynolds equation

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II Fluid Film Bearing Analysis rough surfaces

Pressure flow simulation
on representative surface
Pressure distribution on rough surface

qs=0

Boundary conditions - sealed sides - prescribed pressure difference - no shear velocity Flow rough / flow smooth Filter coefficient pressure increase
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II Fluid Film Bearing Analysis rough surfaces

Shear flow simulation
on representative surface
Pressure distribution under shear

qs=0

Boundary conditions - sides sealed - no pressure difference - shear velocity roughness induced flow

rough flow / shear velocity source

pressure increase

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II Fluid Film Bearing Analysis rough surfaces

Validation: Comparison to analytical solutions by Elrod und Tripp
Roughness is viewed as a stochastic process, characterized by its amplitude distribution and autocorrelation function
Distribution function (Gaussian) Correlation function (exponential decay)

Rough surface Stochastic model

Peklenik factor - ratio of 0.5-correlation lengths x,y

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II Fluid Film Bearing Analysis rough surfaces

Validation: Comparison with Tripps analytical solution
correlation function with elliptical contour lines

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II Fluid Film Bearing Analysis rough surfaces

Validation: Comparison with Elrods analytical solution
correlation function with diamond-shaped / rhombic contour lines

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II Fluid Film Bearing Analysis mixed friction

Solid-to-solid contact determination
Full separation of surfaces Partial solid-to-solid contact

Contact pressure PC [N/mm] Models: fully elastic / ideal plastic

Relative contact area Ac/A

Average gap

Average gap
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II Fluid Film Bearing Analysis mixed friction

Effect of solid-to-solid contact on lubrication
suppression of flow Contact spots
Pressure distribution including solid-to-solid contact

Numerical treatment FEM Contact element No flow condition can easily be fulfilled by leaving out contact elements during assembly of the system matrix in FEM
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II Fluid Film Bearing Analysis mixed friction

Effect of solid-to-solid contact on lubrication at very small gaps elements get disconnected from boundary conditions
Numerical treatment FEM Element with positive gap

Elements in contact

Nodes disconnected from BCs Pressure boundary conditions Areas with positive gap but no connection to pressure boundary conditions must be detected and removed in advance
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II Structural Dynamics Model Reduction

Newtons law of motion Modal Reduction to generalized Degrees of freedom (Ritz vectors)
T T T M v + D v + K v = F T M red Dred K red Fred

+ Du + Ku = F Mu
Modal Shape Vectors

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II Structural Dynamics Multibody System Analysis

Multibody system model
Integration of accelerations and velocities over time System Constraints - Boundary Conditions Multibody + Structural Dynamics

+ Ku = + Du + 2 M u Mu
local deforation

F
ext .loads

+ r + ( r)] M [q
center of gravity

Fluid-Structural-Interaction Reynolds Partial Differential Equation

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