Numerical and Experimental Investigation of Different Oil Levels and Operation Conditions on the Individual Hydraulic Losses of Spherical Rolling Bearings

Improving the energy efficiency of rolling bearings requires a component-resolved understanding of loss mechanisms. While analytical models capture load-dependent losses, load-independent hydraulic losses demand a physics-based approach. This paper presents a computational fluid dynamics (CFD) methodology for the qualification of individual hydraulic loss contributions and to assess their sensitivity to operating conditions. The approach decomposes the total hydraulic loss of the spherical roller bearing 22320 into component-level shares and is benchmarked against dedicated experiments. The simulated results show good agreement with experimental measurements, supporting the validity of the methodology. The discrepancy between the measured and simulated friction torque values averaged at 2–7%, with a single outlier. Furthermore, CFD methods have been demonstrated to be capable of predicting trends in hydraulic losses resulting from variations in speed and temperature. A consistent finding across all investigated conditions is that the rolling elements dominate the hydraulic losses. Churning-induced losses of the rolling elements contribute for more than 50% of the hydraulic losses of the hole bearing in every test. The proposed methodology offers a reproducible way to assign losses individually, compare operating scenarios and guide targeted design measures for loss reduction in rolling bearings. Furthermore, dynamic kinematic simulations of rolling bearings can be equipped with component-resolved hydraulic losses. This is enabling more accurate predictive modelling of the bearing kinematics and detecting effects such as slippage.