An EHD-mixed lubrication analysis of main bearings for diesel engine based on coupling between flexible whole engine block and crankshaft

Purpose - The purpose of this paper is to develop a good calculation model to accurately predict the lubrication characteristic of main bearings of diesel engine and improve the service life. Design/methodology/approach - Based on the coupling of the whole flexible engine block and the flexible crankshaft reduced by the Component Mode Synthesis (CMS) method, considering mass-conserving boundary conditions, the average flow model equation and Greenwood/Tripp asperity contact theory, an elastohydrodynamic (EHD)-mixed lubrication model of the main bearings for the diesel engine is developed and researched with the finite volume method and the finite element method. Findings - Obviously, the mixed lubrication of bearings is normal, while full hydrodynamic lubrication is transient. The results show that under the whole flexible block model, maximum oil film pressure, maximum asperity contact pressure and radial shell deformation decrease, while minimum oil film thickness increases. Oil flow over edge decreases, and so does friction loss. Therefore, coordination deformation ability of whole engine block is favorable to mean load. In the whole block model, friction contact happens on both upper shell and lower shell positions. In addition, average oil film fill ratio at the key position becomes smaller in the whole engine block model, and consequently increases the chances of cavitations erosion more. So, wearing resistance of both upper and lower shells and anti-cavitations erosion ability must be enhanced simultaneously. Originality/value - Based on the coupling of the whole flexible engine block and the flexible crankshaft reduced by the CMS method, considering mass-conserving boundary conditions, the average flow model equation and Greenwood/Tripp asperity contact theory, an EHD-mixed lubrication model of the main bearings for the diesel engine is built, which can predict the lubrication of journal bearings more accurately.