Enhancing Tribological and Lubrication Mechanisms to Improve Mechanical Bearing Durability and Efficiency

ABSTRACT This study considers the tribological performance development of cylindrical roller bearings using the WS 2 –CuO hybrid nano‐lubricant dispersed in biodegradable polyalphaolefin (bio‐PAO). The purpose is to improve the friction reduction, wear resistance, and elastohydrodynamic (EHD) film strength below high‐speed and high‐load operational conditions. WS 2 gives low‐shear lamellar sliding, while CuO nanoparticles improve asperity filling and load‐bearing capacity, creating a synergistic lubrication effect. Laser‐textured bearing surfaces and measured lubricant distribution are combined to achieve steadier lubrication enactment under extreme conditions of 15,000 rpm and 10 kN load. Experimental results display that the improved 0.9 wt% hybrid origination realizes a coefficient of friction of 0.068, representing a 42% reduction associated with base oil (0.120). Wear volume is reduced by 48%, while friction rotation decreases by 35%. The system also displays a 2.5× enhancement in load‐carrying capacity and steady EHD film thickness of 1.22 μm. Particle Swarm Optimization (PSO) is employed to optimize nanoparticle concentration, lubricant flow rate, and surface texture parameters. Upcoming work should focus on long‐term operational validation under real industrial conditions, investigation of nanoparticle stability and agglomeration behavior over extended running cycles, and detailed surface chemistry analysis using XRD and XPS to better understand tribofilm formation. More studies may also explore temperature‐dependent viscosity effects up to 150°C, integration with multi‐bearing systems, and growth of digital twin models for predictive maintenance. Economic feasibility and scalability for automotive, aerospace, and renewable energy applications should also be evaluated to support industrial adoption.