A study of friction in worn misaligned journal bearings under severe hydrodynamic lubrication

Abstract Friction occurs in all mechanical systems such as transmissions, valves, piston rings, bearings, machines, etc. It is well known that in journal bearings, friction occurs in all lubrication regimes. However, shaft misalignment in rotating systems is one of the most common causes of wear. In this work, the bearing is assumed to operate in the hydrodynamic region, at high eccentricities, wear depths, and angular misalignment. As a result, the minimum film thickness is 5–10 times the surface finish, i.e., near the lower limit of the hydrodynamic lubrication when taking into account that in the latest technology CNC machines the bearing surface finish could be less than 1–2 μm. An analytical model is developed in order to find the relationship among the friction force, the misalignment angles, and wear depth. The Reynolds equation is solved numerically; the friction force is calculated in the equilibrium position. The friction coefficient is presented versus the misalignment angles and wear depths for different Sommerfeld numbers, thus creating friction functions dependent on misalignment and wear of the bearing. The variation in power loss of the rotor bearing system is also investigated and presented as a function of wear depth and misalignment angles.