Numerical and Experimental Investigation of Fretting Wear in Connecting Rod Big-End Bearings of Nuclear Emergency Diesel Generators

The operational reliability of Emergency Diesel Generators (EDGs) is paramount for the safety of nuclear power plants. This study investigates the fretting wear mechanism on the non-working back-face of connecting rod big-end bearings—a critical failure mode that can lead to catastrophic engine damage. A synergistic approach was employed, integrating theoretical pressure calculations, on-site strain measurement experiments, and high-fidelity non-linear finite element analysis (FEA). The results demonstrate that while the theoretical design back-face pressure ranges from 8.1 to 10.1 MPa, the actual pressure is highly sensitive to bolt preload. A 16.2% attenuation in preload (from 550 kN to 461 kN), common during maintenance cycles, causes the interfacial pressure to drop to 6.9 MPa, falling below the recommended safety threshold of 7 MPa required to inhibit fretting. Furthermore, comparative experiments reveal that used bearings exhibit significantly lower and less uniform radial pressure retention compared to new bearings, even when physical dimensions appear compliant. Dynamic FEA indicates that peak inertial loads induce an out-of-roundness (DOR) of 0.295 mm, triggering a transition from a “partial slip” to a “macro-slip” regime at the interface. The findings confirm that the coupling of preload attenuation and loss of bearing elasticity drives the fretting process, providing a theoretical basis for optimized maintenance and selective assembly strategies.