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Experimental Tribological Performance Analysis of Aluminum Based Hydrodynamic Journal Bearing.

1
 journal bearings use the rotational movement of the journal to
pressurize lubricating oil which is supplied to bearing to avoid
Experimental metal to metal contact and sustain the load.

Tribological Performance
Analysis of Aluminum
Based Hydrodynamic
Journal Bearing.
Vaibhav Jadhav1, Prof. P. P.Ritapure2
Fig. 1 Journal Bearing
Abstract—The aluminum based materials are widely used in Journal bearing surfaces are divided into three lubrication
highly performance bearings application. In the present work, regimes corresponding to the Stribeck Curve shown in figure 2.
New Aluminum based Al-25Zn-5Cu alloy material is produced by The curve represents the minimum value of friction torque
metal mould stir casting technique. The aim of research work to between large fluid separation and contact of two surfaces. The
investigate tribological performance of hydrodynamic journal highest friction occurred in boundary lubrication region, which
bearing made of Al-25Zn-5Cu alloy material were analyzed represents contact between the two surfaces also the
experimentally and a comparative study between two different hydrodynamic lubrication region represents a load supported
hydrodynamic journal bearing made of materials Al-25Zn-5Cu by the lubricating oil with no contact of surfaces. At the end the
and Brass were analyzed. The oil temperature rise, pressure mixed lubrication region represents mean load support from
distribution, surface roughness, weight loss were calculated for
lubricating oil and some of load support from contact.
different loads, speed and times range. It was found that pressure
distribution were developed more in Al-25Zn-5Cu alloy material
as compare to brass material journal bearing. At the end wear
analysis of two different hydrodynamic journal bearing
investigated by using surface roughness and weight loss. Further
the weight loss, surface roughness and oil temperature rise were
observed less in Al-25Zn-5Cu alloy bearing as compare to brass
bearing. As experimental results shows that aluminum based
hydrodynamic journal bearing can be an alternative for the
existing brass bearing with improving tribological properties and
performance of journal bearing.

Keywords— Journal bearing, Al-25Zn-5Cu, Tribology, Wear.

Fig. 2 Stribeck curve with different lubrication regimes

I.INTRODUCTION
H generated in lubricating oil to carry the load. These conditions
YDRODYNAMIC journal bearings are important component of all
rotating machinery. The Hydrodynamic journal bearing are
support radial load under high speed conditions. In the
operating condition of hydrodynamic journal bearing inner
pressure generates film of lubricating oil in between journal and
bearing to prevent journal to bearing contact as shown in
figure1.Under working operating conditions lubricating oil
undergoes a change in viscosity due to change in oil thickness
and temperature so that journal is get contact with bearing
surface as thickness of oil decreases then failure of Journal
bearing are mainly depends upon the bearing surfaces
mechanical and tribological properties. The Hydrodynamic
The more wear of journal bearings developed during boundary
and mixed lubrication conditions when there is less pressure
occurred during starting, stopping and low speeds of journal
rotation. The more amount of wear in journal bearings surfaces
will reduce performance over time and can result in bearing
failure. The failure of a journal bearing has significant effect on
production losses and maintenance costs. From recent study on
bearing wear rate is dependent upon operation of starts and
stops also on journal Speed, load range, material hardness. The
Journal bearings are widely used in machinery, engines and
vehicle industry. However most of the journal bearing system
would have lack triabological compatibility due to tendency to
avoid contact between two materials sliding under conditions
of solid friction because of the breakdown of lubricant film
occurs. Fatigue damage may represent an intergranular crack in
the bearing material. The cracks are developed in opening

1Vaibhav
T. Jadhav, PG student, Mechanical Engineering Department, ZES’s, Prof. P. P. Ritapure, Professor, Mechanical Engineering Department , ZES’s,
ZEAL College of Engineering & Research, Narhe, Pune-41. ZEAL College of Engineering & Research, Narhe, Pune-41.

Experimental Tribological Performance Analysis of Aluminum Based Hydrodynamic Journal Bearing.
direction of rotation. A Pieces of bearing material may spread
out also pulled away in direction of rotation of journal. The
cracks extend toward the bearing material bonding particles.
Fatigues can develop due to because of misalignment,
imbalance, bent shaft, journal eccentricity, and vibration. The
Corrosion damage is a removal of the bearing surface lining by
chemical attack. Corrosive materials were get in contact with
lubricating oil due to decomposition of oil additives, acid
oxidation, water in lube oil, corrosive contamination. Erosion
damage developed in material voids with smooth edges in the
direction of rotational moment. Most of the time damage
occurred in stationary component. Cavitation damage is
developed due to the formation of vapour bubbles in areas of
rapid pressure differences.
II.RESEARCH BACKGROUND
The journal bearing are operating under steady subjected to
wear during start-up and start-down, contamination with
abrasive debris and misalignment of shaft also working under
high temperature and overload would be wear under load
reported by M.M.Khonsari et.al.[1].The major problem of
white metal is seiziure when lubricating film is broken under
heavy load studied by D.G.lee.et.al.[2].Therefore there is scope
for research on journal bearing material to improve mechanical
and triabological properties. From recent study reported that
Osman Bican et.al. [3] developed aluminum–zinc-based a new
alloy for tribological application. A new Al-25Zn-5Cu was
prepared by mould casting and their microstructure and
mechanical properties were investigated. The sliding friction
and wear properties Al-25Zn-5Cu alloys were found out using
a pin-on-disc machine. The highest hardness and tensile
strength were obtained with the Al–25Zn-5Cu alloy among
tested among standard material. Addition of copper to this alloy
increase hardness with increasing copper content. The highest
tensile and compressive strengths and wear resistance and
lowest friction coefficient were obtained in Al–25Zn–5Cu alloy
also Al-25Zn-5Cu alloy were found superior as compared to
SAE 660 bronze for mechanical and sliding wear
properties.Nehir et.al.[4] investigated the performance of Al-
based material studied experimentally. The Al-based bearing
materials have higher fatigue strength than white metal bearings
and can be used at high working temperature. The aluminum
based alloys have good material properties like resistance to
corrosive effects, low cost, high thermal conductivity, lightness
and workability. The aluminum based alloys are developed to
use in high performance engine bearings. The main factor
improving the efficiency of the internal combustion engine is
usage of aluminum alloy. Yasin alemdag et.al.[5] examined the
microstructure of Al-40Zn-Cu alloy consists of aluminum rich
surrounded by CuAl2 particles. Hardness of alloy increases
continuously with increasing copper content. The Al-40Zn-Cu
alloy were found to much superior than SAE65 bronze for wear
resistance and higher strength. Temel savaskan [6] investigated
friction wear properties of Al-25Zn-3Cu alloy over a range of
oil flow rate, pressure and sliding speed using pin on disc
machine. The obtained results were compared with
conventional bearing material SAE65 bronze. The friction
coefficient and wear volume of the alloy decreases with
increasing oil flow rate. The Al-25Zn-3Cu alloy has higher
2
wear resistance as compared to the bronze.Smearing type of
adhesion appeared to be the most effective wear mechanism for
the Al-25Zn-3Cu alloy. Al-Zn alloy containing small amounts
of copper are increasing the importance as a bearing material
also Zinc and aluminum based alloy containing 40%Al and 2%
Cu exhibited better tribological properties. Zn-Al based alloy
had better seizure resistance at load less than 175N.A excellent
embeddability and good running-in properties were
demonstrated for bearing.H.C.Patel.et.al. [7] investigated the
performance of ferrofluid based hydrodynamic journal bearing
system considering different combination of shaft and bearing
material. Film pressure and temperature rises were measured
for varying speeds and loads also wear analysis was carried out
using microscopic observation of the bearing surface, weight
loss. The life of hydrodynamic journal bearing life when the
contacting surface occurs at bearing surface studied by David
sander et.al. [8].The results show that wear is caused by metal-
metal contact due to the elastic bending of shaft also maximum
contact pressure in mixed lubrication decrease with adapted
surfaces. The adapted surface is due to shaft speed, surface
roughness and temperature. The main reason for more
innovation in the journal bearing is the set of specific properties
to which material has to withstand the load. If we consider from
chemical point of view, material have to be corrosion resistant,
toxicity. A high thermal conductivity is important to transport
the heat dissipated, a low coefficient of expansion is
advantageous in journal bearing and a high melting point is
required to maintain sustainable strength at the operating
temperature studied by A. E. Bravo et.al. [9]. To reduce power
loss and increase load carrying capacity of journal bearing a
various approaches focus on journal bearing design.
D.A.Bompos et.al.[10] investigated performance of multistep
journal bearing. A maximum friction coefficient improvement
of 38% is obtained with simultaneous 9.7% improvement of
load capacity as compare to plain bearing. F.M.Meng et.al.[11]
studied tribological performance for the bearing with
compound dimple and simple dimple. The results shows that
compound dimple supply larger load carrying capacity and
lower friction coefficient due to its twice hydrodynamic action
in comparison with the simple dimple. Hydrodynamic Journal
bearing are used in different rotating machine. This type of
bearing working under large load at mean rotational speed but
in some cases the machine fitted with these bearing can operate
at very high rotation speed condition. So when bearing is
working at high rotation speed there is possibility of failure.
Therefore this limits the load acting on bearing surface and
working speed of journal. Therefore it is significant to know the
load and speed above which bearing will failure. The frictional
force plays important role in journal bearing design. Frictional
force decreases the rotation speed, load carrying capacity and
surface finish which cause failure of journal bearing.
Most of existing studies are deal with journal bearing
lubrication parameters, journal bearing design. In addition,
none of us focused on to studied journal bearing performance
made up of Al-25Zn-5Cu material having better properties as
compared to other classical bearing material so that the aim of
proposed work was to investigate the performance of
hydrodynamic journal bearing made up of Al-25Zn-5Cu
material experimentally using journal bearing test rig under
 3
Experimental Tribological Performance Analysis of Aluminum Based Hydrodynamic Journal Bearing.
different parameter such as load, rotational speed, surface will be placed in the range of 200N to 800N.To the other side
roughness, pressure distribution, oil rise in temperature, weight is mounted a ball bearing through which normal load is applied
loss. In the proposed work performance analysis of to the bearing surface. Lever is located to get 1:5 loading ratio.
hydrodynamic journal bearing is carried out of dimension (L/D The oil filling system is provided on the top of base plate to
=1),speed range of 800 to 1400rpm and load range of 200 to gravity feed the bearing by using a flexible tube before start of
800 N on a journal bearing test rig. A New Hydrodynamic testing to remove any trapped air. An oil sump is mounted to
journal bearing made of Al-25Zn-5Cu MMC material is supply continuous lubrication for the journal bearing system.
developed to improve tribological properties and results were The oil sump is placed on bottom base plate, which is fixed on
compare with brass material journal bearing. to the supporting structure member.
The Testing parameter such as disc speed can be set using front
III. EXPERIMENTAL PROCEDURE panel settings on the controller. The load is applied by dead
A. Description of Experimental Setup weights through loading lever assembly. The pressure and
torque readings are displayed along with indexing angle during
The hydrodynamic journal bearing test rig is known for found testing. Pressure and angle readings are processed and
out the film pressure distribution in a lubricating oil under transmitted through data acquisition cable. The Port’s for signal
different load condition also measure frictional torque. This is input cable and data acquisition cable MS connector for control
a vertical machine which helps to find out pressure at respective cable and fuse. Data acquisition software having data
angular position of pressure sensor with the load chain. The acquisition cable and one CD containing winducom 2004
Hydrodynamic journal bearing machine contains a vertical software.
journal and driven under different speed by motor. A bellow
made up of metal joints journal bearing material at top and Table 1 Specifications of Al-25Zn and brass bearing systems.
bottom is fixed to friction torque load cell. The hydrodynamic Al-25Zn-5Cu Brass
journal Bearing made of Al-25Zn-5Cu and brass material which Specifications bearing bearing
covered the journal lower portion also these bearing is dipped system systems
into oil sump. The speed sensor disc is located on the driven Material
Al-25Zn-5Cu Brass
pulley to calculate the revolution of the journal per minute. A
stepper motor rotate the hydrodynamic journal bearing in the Journal bearing roughness
direction of the rotation of the journal up to 180° in steps of (Ra) 0.5 0.6
9°.A pressure sensor is fixed on the journal bearing which
calculate the film pressure distributed in the lubricating oil film Journal Material
AISI410 AISI410
layer. The Radial load is applied to journal bearing by dead
weights through a lever chain mechanism. The assembly of the Journal surface roughness
journal and the bearing is dipped into oil sump to have (Ra) 0.3µm 0.3µm
continuous lubrication. The journal bearing machine is
connected to the controller. The controller shows reading values Inner diameter of bearing
40.12mm 40.12mm
of rotating position of pressure sensor with reference to the load
and the respective pressure values. The perpendicular load, Diameter of journal
39.97mm 39.97mm
speed can increase as per testing load case data. The Frictional
force value can also be showed on the controller. The output Length of bearing
40.00mm 40.00mm
data obtained are transfer to computer through data acquisition
cable line. Clearance 0.07mm 0.07mm
B. Material for Journal Bearing System
The importance of the use of aluminum metal matrix composite
reinforced with Zinc in engineering application lies in the
excellent characteristics such as light weight, increases strength
also reduce ductility and corrosion resistance. The Stir casting
is a liquid state method of composite material fabrication in
which a dispersed phase is mixed with a molten matrix metal
by means of mechanical stirring.
Fig. 3 Journal bearing test rig.
The journal bearing test rig consists of bearing assembly,
journal shaft assembly, lubricating oil system, sensors, loading
assembly, controller, data acquisition software and cables.
Journal is inserted in spindle housing supported on bearing.
Spindle housing is fixed to base plate. Journal shaft is rotated
by an AC motor through pulley chain arrangement. The rpm
sensor disc is mounted on top of spindle to measure speed. A
lever is provided having a lever ratio of 1:5.The one end of the
lever a loading pan is attached on which the different weights

Experimental Tribological Performance Analysis of Aluminum Based Hydrodynamic Journal Bearing.
Fig. 4 Stir casting process of Al-25Zn-5Cu material
The preparation of metal matrix composites by stir casting
process some of the parameter that need to be attention is to
achieve uniform distribution of the reinforcement material and
obtain sufficient wettability between the two main substances
also reduce porosity in the cast metal matrix composite. A 10kg
of pure aluminum is melted at 660.3 degree in furnace then 2kg
700gm of pure Zinc is melted at 419.5degree in same furnace
after that 300gm of pure copper is melted at 1085 degree. The
process parameter of stir casting should be properly controlled
to obtain best metallurgical properties of material are stirrer
design, stirrer speed, stirring temperature ,stirring time ,preheat
temperature of reinforcement ,preheated temperature of mould,
reinforcement feed rate, wettability-promoting agent, Pouring
of melt.
C. Production of Al-based Journal Bearing
The Al-25Zn-5Cu metal matrix composite material is prepared
by stir casting technique. Once molding material is prepared
then its material is removed by turning operation to get desired
dimension of diameter and height. The exact desired
dimension work piece is fitted on fixture of vertical milling
center (VMC) machine.
Fig. 6 Al-25Zn-5Cu and Brass Journal Bearing
The movement of milling tool is depending on program that
feed to the VMC machine. The program needs to require 3D
modeling of bearing as per the CAD drawing details. The
milling tool will remove the material as the 3D model and after
that drilling machine is used to create the hole in the bearing
then hand tapping is used for generation of thread on surfaces
as per dimension. The process of journal bearing is completed
with accurate quality.
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D. Test Procedure
The fabricated hydrodynamic journal bearing made of Al-
25Zn-5Cu and Brass material is mounted on Journal bearing
test rig alternatively for testing. The experimental analysis was
carried out on both bearing system for different loading
conditions at different journal speed. Firstly pressure
distribution was measured at different loads and speeds then
wear analysis was conducted for journal bearing under
lubricated condition with frequent starts and stops because
maximum wear occur in journal bearing while starting and
stopping. The Wear loss, surface roughness in both journal
bearing measured after 50 cycles of starts and stops based upon
researcher works. The oil temperature rise is measured under
different speed and constant load for continuous run of 1hours
time.
E. Taguchi Method
Standard orthogonal L16 array was used to conduct the
experiments for selection of speed and load range values. The
number of speed and load range values will get from the
researcher work on journal bearing.Taguchi method
considerably less the total of experiments that are necessary to
model the reaction function compare with the full factorial
design of experiments. The main profit of this method is to sort
out the possible interface between the parameters. The Taguchi
procedure is originate for procedure optimization and
identification of optimal associated of the elements for a given
response. But the design-of-experiments (DOE) is a scientific
approach to effectively design and developed experiments
using statistics. In such designs, the combination of each
element at every stage is studied to determine the combination
that would yield the finest outcome. DOE is a significant
investigation tool for modeling and evaluating the influence of
control elements on performance output. The most important
phase in the DOE lies in the selection of the control factors.
Therefore, a large number of factors are initially included so
that the less significant variables can be identified at the earliest
opportunity.
IV. RESULTS AND DISCUSSION
The experimental performance analysis is carried out of Al-
25Zn-5Cu and brass material bearing on journal bearing test rig
also wear analysis were carried out on Al-25Zn-5Cu as well as
brass bearing. To find out the pressure distribution and
temperature rise, the experimentation was performed under
different speed and applied load. The results obtained from the
experimental analysis were presented graphically and tabular
form. Then to understand the wear analysis required having
frequent starts and stops of 50 cycles were taken on journal
bearing under lubricating oil.
A. Pressure Distribution
The pressure distributions in the hydrodynamic journal bearing
were obtained under different loads and speeds. The pressure
distribution of Al-25Zn-5Cu and brass material bearing were
measured alternatively on journal bearing test rig. The
 5
Experimental Tribological Performance Analysis of Aluminum Based Hydrodynamic Journal Bearing.
experimental testing output value of pressure distribution is As seen from figure7 shows that the maximum pressure is
shown in below table under different loads and speeds obtained in Al-25Zn-5Cu bearing system as compare to brass
conditions. The different load and speed values are taken based bearing system due to tribological and mechanical material
upon research background with support of DOE parameter. The properties. The maximum pressure distribution developed in
pressure distributions are measured under different speeds like Al-25Zn-5Cu journal bearing system is 3590.8 KPa whereas in
800,1000,1200,1400 rpm and different loads are brass bearing system 2185.1 under high speed and high load.
200,400,600,800N under working conditions. The minimum pressure developed in Al-25Zn-5Cu bearing
system is 735.6 KPa and for brass bearing system 510.4 KPa.
Table 2 comparison of pressure distribution in different journal bearing. The pressure distribution developed in Al-25Zn-5Cu bearing
system is almost double as compared to brass bearing system
Tr. Speed Load Pressure distribution(KPa) under high speed and high load. The pressure distribution
No. (rpm) (N) results shows that at constant load and increasing speed of
Brass Al-25Zn-5Cu
journal pressure distribution is decrease as journal position
1 800 200 510.4 735.6 changes at high speed also pressure distribution at constant
2 1000 200 492.3 704.3 speed and increasing the radial load on the bearing the pressure
distribution increases.
3 1200 200 458.9 690.1
4 1400 200 498.3 712.2 B. Temperature Rise in Oil
5 800 400 1070.1 1470.8 The oil temperature rise in Al-25Zn-5Cu and Brass bearing
system is measured by using thermocouple attached to journal
6 1000 400 1132.7 1670.9 bearing test rig. A journal bearing system continuously running
7 1200 400 1007.4 1408.3 for 30 minutes to find out oil temperature rise in bearing system.
The temperature of journal bearing system is measured is
8 1400 400 972.9 1380.4 shown in below Table3
9 800 600 1570.3 2530.9
Table 3 comparison of oil temperature in different journal bearing.
10 1000 600 1636.9 2643.4
11 1200 600 1675.2 2683.1 Tr. Speed Load Oil temperature rise of 30 minutes of
No. (m/s) (N) continuous run
12 1400 600 1720.5 2706.5
Brass Al-25Zn-5Cu
13 800 800 2120.5 3625.2
1 800 800 39°c 29°c
14 1000 800 2203.4 3670.7
2 1000 800 55°c 41°c
15 1200 800 2210.3 3649.5
3 1200 800 82°c 59°c
16 1400 800 2185.1 3590.8
4 1400 800 112°c 79°c
The pressure distribution values were measured with increasing
speed from 800 to 1400 rpm and kept the constant load The experimental testing results show that higher oil
200,400,600,800N alternatively. The comparison of pressure temperature is observed in brass bearing it’s around the 112°c
distribution of Al-25Zn-5Cu and brass journal bearing is show whereas for Al-25Zn-5Cu bearing system is 50°c under high
in figure7 under different speed and loads conditions. speed and high load of the journal bearing system. The lower
oil temperature is observed in brass bearing is 39°c and for the
Al-25Zn-5Cu bearing system 29°c under low speed and low
load.

Fig. 7 Pressure Distribution vs. No.of trials of journal bearing


Experimental Tribological Performance Analysis of Aluminum Based Hydrodynamic Journal Bearing.
Fig. 8 Temperature vs No.of Trails of journal bearing
The comparison of experimental oil temperature rise in brass
and Al-25Zn-5Cu bearing system shown in the Figure 8. The
oil temperature rise of both journals bearing system running
continuously 30 minutes under constant high load 800N and
speed of journal increasing from 800,1000,1200,1400 rpm
shows that temperature is increasing rapidly and decreases the
viscosity of lubricating oil. In Brass bearing system oil
temperature rise is from 39°c to 112°c due to brass having
higher melting point so that brass bearing system does not
absorb the heat and transfer to surrounding for continuously
cooling however in brass system temperature oil increasing and
decrease the oil viscosity tends to decreases the oil film
thickness. In Al-25Zn-5Cu bearing system oil temperature rise
from 29°c to 79°c due to lower melting point as compare brass
bearing so that Al-25Zn-5Cu bearing system absorb the heat at
low temperature and also transfer the heat to surrounding hence
oil temperature is not increase the suddenly having high thermal
conductivity properties compare to brass bearing. The pressure
distribution developed more in Al-25Zn-5Cu bearing as
compare to brass bearing due less oil temperature rise and will
not break the oil thickness and viscosity.
C. Weight Loss and Surface Roughnes
The weight loss and surface roughness of brass and Al-25Zn-
5Cu bearing were calculated before and after the experimental
test of 50 cycles of start and stops done on journal bearing test
rig.
Table 4 comparison of weight and roughness in different journal bearing
Sr. Journal Surface
Weight
No. bearing roughness
(gr)
system (Ra)
Before After Before
Test Test Test
1 Brass 1620 1400 0.6
2 Al-25Zn-5Cu 614 600 0.5
The weight loss is measured after test and before test by using
weighing machine and surface roughness is measured by using
surface finish measurement instrument. The values of weight
6
loss and surface roughness are shown in Table 4 with before
and after test of 50 cycles of start and stops. It can be seen from
the Table 4 shows that weight loss in Al-25Zn-5Cu bearing
system less compared to brass bearing system. The Al-25Zn-
5Cu journal bearing is very light having weight as compare with
brass journal bearing system. After the experimental test weight
of Al-25Zn-5Cu journal bearing system is 600gr whereas for
brass is 1400gr so that material is wear more of brass as
compared to Al-25Zn-5Cu journal bearing also the surface
roughness value of Al-25Zn-5Cu bearing before the
experimental test is 0.5 and after experimental test is 0.8
whereas surface roughness value of brass bearing before the
experimental test is 0.6 and after the experimental test is 0.9.it
shows that more wear resistance, light weight and low cost
observed in Al-25Zn-5Cu bearing as compare to brass bearing.
V.CONCLUSIONS
The present research work investigated performance of journal
bearing made of Al-25Zn-5Cu and brass materials using journal
bearing test rig and other measurement instruments. The
experimental testing results are compared between Al-25Zn-
5Cu and brass journal bearing system. The result shows
hydrodynamic journal bearing made of Al-25Zn-5Cu material
superior than existing brass material hydrodynamic journal
bearing in terms of performance parameters and life period and
cost point of view. The Conclusions involved are as follows:
1. The Al-25Zn-5Cu journal bearing system shows more
pressure distribution than brass journal bearing system.
2. The oil temperature rise is less in Al-25Zn-5Cu bearing
system as compared to brass bearing system.
3. The amount of wear and weight in Al-25Zn-5Cu journal
bearing is lower than brass journal bearing under similar
tribological loading conditions.it shows that service life of Al-
25Zn-5Cu bearing to be longer than brass bearing.
4. The Al-25Zn-5Cu bearing system has lower surface
roughness than brass bearing system.
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