Influence of Geometric Parameters on Journal Bearing Wear: A Finite Element Analysis and Elastic Foundation Approach

This study investigates the influence of geometric parameters on wear of journal bearings within a multibody system framework. While extensive research has explored the impact of wear on journal bearing performance, limited attention has been given to the role of geometric parameters in wear progression. To address this gap, this study examines the effects of bushing depth, internal and external bushing diameters, and bushing rim thickness on wear in a non-lubricated journal bearing joint within a slider–crank mechanism. The joint consists of a 347 stainless steel journal and a PTFE bushing operating under moderate loading conditions (0.25 MPa to 5 MPa) and low sliding velocities (1 mm/s to 10 mm/s). Wear predictions are conducted using the elastic foundation model (EFM) and finite element method (FEM), with multibody dynamics analysis providing joint force estimations. The results from both approaches reveal that (1) increasing bushing depth reduces both wear volume and maximum wear depth, (2) bushing outer diameter has little to no effect on wear volume and maximum wear depth, (3) smaller bushing rim thicknesses lead to greater wear volume, and (4) larger bushing depths reduce both wear volume and maximum wear depth. Consequently, it is recommended that journal bearings designed to minimize wear should have smaller inner diameters, with attention to the stress effects on the journal due to the reduced diameter. Additionally, small bushing rim thicknesses should be avoided, and larger bushing depths should be considered to reduce wear. These insights contribute to the optimization of journal bearing design for improved durability and performance in mechanical systems.