Inlet Oil Research Articles

A Starved Lubrication Model: Applications to Evaluate Gear Mesh and Response Prediction of Material Plasticity

This study presents a model of starved mixed Elastohydrodynamic Lubrication (EHL) in point and line contact to investigate the lubrication performance and material response. In formulating the governing equations for the lubrication, the dimensional Reynolds equation is discretized to involve all possible regimes from the boundary lubrication to fully hydrodynamic lubrication, and an additional algorithm is provided to determine the fractional film content based on the profiles of pressure distribution and film thickness. Solutions of the point contact from the present model are compared with those reported by the previous studies and good consistency can be found. The three-dimensional line contact is used to predict the load carrying capabilities of the film thickness at the interface of mating spur gear teeth. A return mapping method is implemented to take the plastic revolution into account. The solution at the initial stage of a startup process with the lubricant entrainment velocities of ux = uy = 0 is compared with that from a dry contact to validate the elasto-plastic solutions. Sample cases are presented to reveal the effects of inlet oil supply condition and material plasticity on lubrication starvation.

Study on lubrication characteristics of multi-layer structure hinge under the influence of clearance dynamic

This paper presents a methodology for investigating the lubrication characteristics of multi-layer structural mechanical hinges based on clearance dynamics. By multi-layer hinged structures, we mean the four mediums: the journal, lubricating oil film, bearing sleeve, and connecting rod. Initially, a dynamic model that incorporates clearance is established using the automatic dynamic analysis of mechanical systems, revealing that the primary contact area is located between 50° and 70°. Subsequently, a lubrication model for the multi-layer structural mechanical hinge is constructed using ANSYS FLUENT software, which demonstrates the effects of critical parameters—such as contact angle, sleeve installation angle, inlet pressure, and shaft neck speed—on lubricant flow, pressure, and void fraction. The findings indicate that the motion offset angle significantly influences the pressure distribution within the oil film area, with high-pressure and low-pressure zones oriented counterclockwise and clockwise, respectively, relative to the offset angle axis. Furthermore, as the distance between the offset angle and the oil inlet increases, the volume fraction of cavitation decreases from 1.77% to 1.16%. When the sleeve installation angle aligns with the motion offset, the volume fraction of cavitation reaches 1.9%. Conversely, when the assembly angle aligns the oil inlet hole with the injection hole, the volume fraction of cavitation is minimized to 0.36%, resulting in an approximate performance improvement of 81.11%. This study provides a theoretical foundation for optimizing the lubrication design of multi-layer structural mechanical hinges and offers substantial guidance for the lubrication of mechanical hinges.

Simulation Approaches for the Study of the Oil Flow Rate Distribution in Lubricating Systems with Rotating Shafts

This study addresses the issue of predicting the distribution of lubricant flow through the outlets of a rotating shaft used in vehicle power transmission. A typical geometry with closely spaced rows of holes, suitable for the lubrication of multi-disk clutches, was considered. Both lumped parameter and computational fluid dynamics approaches were applied and compared. The test rig for model validation was designed with a variable speed shaft featuring an axial oil inlet and three equally spaced pairs of radial outlet holes. The main characteristic of the experimental facility is the possibility to selectively measure the flow rates through each outlet. It was found that the three-dimensional model based on the multiple reference frame approach provides a reliable prediction of how the flow rate is distributed. Generally, the flow rate is lower through the outlet closest to the inlet and is maximum at the farthest exit. The flow distribution is minimally affected by the shaft speed. The influence of geometric parameters on making the flow distribution more uniform was studied. It was found that a better flow balance is obtained with a low ratio between the diameter of the radial holes and that of the axial channel. The results obtained offer best-practice guidelines for accurately simulating comparable systems, in order to optimize reliability of the mechanical transmission and energy efficiency of the flow generation unit.

Numerical study of swirl core-annular flow and factors influencing pressure drop in vertical pipelines for oil-water two-phase flow

As oil field production progresses, the water content of the produced fluid increases and wax deposits form on the pipe wall as the crude oil is transported vertically through the pipeline. This causes the cross-sectional area of the pipeline to decrease, the flow resistance to increase and the pipeline pressure to decrease. As a result, production from oil wells declines and extraction costs rise. Therefore, in the current study, a vortex structure is utilized to generate a vertical core-annular flow for oil production and transportation in high-water-content oil wells. This study uses computational fluid dynamics (CFD) software to investigate the influence of various oil properties on the oil phase distribution and pressure drop in core-annular flow in vertical pipes. The findings demonstrate that the ring-forming effect of the core-annular flow increases with larger oil droplet sizes and lower oil phase densities, while it becomes weaker with higher inlet oil phase volume fraction and lower inlet velocities. As the size and density of the oil droplets grow and decrease, respectively, the pressure drop reduces. On the other hand, the pressure drop increases with higher inlet oil phase volume fraction and viscosity. When the oil droplet size is greater than 0.2 mm, the density is less than 850 kg/m3, the oil phase volume fraction is less than 30% and the inlet velocity is greater than 1 m/s, the annular flow works better. When the inlet oil phase volume fraction is above 30%, and the ring formation effect decreases significantly. The utilization of swirl core-annular fluid significantly mitigates the pressure drop in pipelines compared to pure oil transport downhole, rendering it highly suitable for conveying crude oil in high-water-content oil wells.

Principle and pressure loss experiment of electro-hydraulic slide-rotary direction valve in single-pump and multi-motor hydraulic system

To better realize direction control of the single-pump double-motor hydraulic system and simplify the system, structure and principle of a six-position six-way direction control valve was proposed, which the valve spool has two motion modes: sliding and rotating. Using this valve, the inner and outer motors can work independently and simultaneously. The pressure loss of the valve was tested by building a transmission system, and the experiment results were compared with theoretical analysis. The results show that the performance of the valve working in left and right positions is better than that in meso-position, and the maximum pressure loss occurred in meso-position. Under the rated flow, the maximum pressure loss is 0.331 MPa. Then the characteristic curve of flow-pressure loss and the relationship of pressure loss among oil ports are obtained. In the same conditions, except that the oil inlet pressure loss in the meso-position is greater than the oil outlet pressure loss, the oil inlet pressure loss in the left and right positions are less than the oil outlet pressure loss, the pressure loss in the forward position is less than the pressure loss in the reverse position. The experiment verifies the correctness and feasibility of the structure and principle.

Mechanism analysis of burn-up failure for needle roller bearing at high-speed gear in manual transmission

Adequate lubrication conditions of needle roller bearings are crucial for the normal operation of transmission. Addressing the burn-up and adhesion failures of needle roller bearings during transmission bench trials, two rigid body rotation physical models were developed to analyze and model the lubrication effect on the inner and outer surfaces of needle roller bearing. Through theoretical analysis and lubrication simulation, it was found that under the critical condition of d/D=0.553, the centrifugal force F on the outer ring surface of the needle bearing was related to the density of lubricant, rotational speed, as well as the angle and size of oil hole, rather than the position of the oil holes; Moreover, the centrifugal force F on the needle roller bearing at input shaft was related to the speed of transmission gear and was also associated with the clearance size between needle roller and cage. Theoretical analysis, simulation, and experimental results have demonstrated that the lubrication performance of needle roller bearings during operation at lower rotary speed gears was inferior to that at higher speed gears, and the lubrication was also less effective when the cage clearance was narrower. Employing angled oil inlets (holes), appropriately enlarging the diameter of oil inlets (holes), and increasing the clearance width between needle roller and cage will contribute to the improvement of lubrication effect.

Heat transfer characteristics of oil receiving and delivering process in crude oil storage tanks

The study used numerical simulation methods to investigate the influence of different oil receiving and delivering cases on the non-uniform physical field within the storage tank. The results showed that the evolution of the physical field can be divided into three stages: diffusion, suppression, and equilibrium. The computational domain was divided into three zones based on the crude oil heating rate: significant influence zone, indirect influence zone, and minimal influence zone, and the indirect influence zone exhibits the most pronounced variations in velocity and temperature. The process of receiving oil with high-flow rate and low-temperature was found to be more conducive to the full use of heat in the tank when the heat exchanging quantity per unit time was the same. The synergistic effect of tubular heating and oil receiving and delivering resulted in a 21 % higher average temperature increase rate than the sum of the two processes. Finally, the study quantitatively described the linear relationship between the average temperature in each region and factors such as oil inlet velocity, oil receiving temperature, oil receiving and delivering time, and heating tube temperature, providing theoretical guidance for process planning in actual oil storage tank receiving and delivering.

Insights into water-lubricated transport of heavy and extra-heavy oils: Application of CFD, RSM, and metaheuristic optimized machine learning models

With diminishing light crude oil reserves, the focus shifts to heavy and extra-heavy crude oil, posing challenges with high viscosity impeding flow. Water-lubricated technology addresses this issue in oil transmission lines. This study introduces a novel method integrating response surface methodology (RSM), computational fluid dynamics (CFD), and optimized machine learning (ML) models to analyze pipeline pressure gradients (PG) in oil–water two-phase flows downstream of T-junctions. The present study uses the D-optimal technique for simulation design to optimize CFD computational demands efficiently. This study breaks new ground by proposing a framework that leverages support vector machines (SVMs). The proposed framework incorporates metaheuristic optimization algorithms (genetic algorithm (GA) and particle swarm optimization (PSO)) to achieve superior PG prediction accuracy. The optimized ML models outperformed RSM models for predicting PG. Results indicated that oil-to-water viscosity ratio and oil inlet velocity significantly affect PG, followed by water inlet velocity and surface tension between phases. In contrast, the oil-to-water density ratio, oil entry angle at the T-junction, and wall contact angle have minimal impact. Furthermore, statistical metrics and visual comparison tools identified the PSO-optimized SVM model based on linear kernel function as the most effective (MAPE = 13.2 % and R = 0.9949). The hybrid methodology presented in this research holds significant promise for optimizing heavy oil transfer efficiency in applications involving water-lubricated technologies.

Impact of oil supply conditions on water lubrication assisted with minimal secondary lubricating medium

Abstract Previous research has revealed that introducing a secondary lubricating medium can temporarily enhance water-lubricated bearing performance, thereby reducing the risk of lubrication failure under challenging conditions. This study aims to identify the optimal injection point for the secondary lubricating medium and evaluates oil supply rate effects. Experiments are conducted using a block-on-ring test rig, complemented by CFD simulations to elucidate the underlying mechanisms. Three oil supply settings, upstream, inlet and outlet of the contact region, are compared. Results shows that upstream oil supply led to a lower critical speed at which the added oil loses any effect compared to the inlet oil supply and outlet oil supply. The effect of oil supply rates on friction reduction varies among the oil supply settings and ring rotational speeds. In conclusion, the most effective oil supply setting positions the injector at the outlet of the contact region, outperforming placement at the entrance of the contact region.

Research on the Support Performance of Internal Feedback Hydrostatic Thrust and Journal Bearing Considering Load Effect

This study aims to analyze the impact of uniform and eccentric load conditions on the performance of internal feedback hydrostatic thrust and journal bearing. Two distinct models are established: a three-degrees-of-freedom uniform load model and a five-degrees-of-freedom eccentric load model. The support stiffness, overturning stiffness, and flow rate for both thrust and journal bearings are calculated. Additionally, numerical analysis is conducted to examine the influence of oil film thickness, inlet pressure, and restrictor size on the operational characteristics of the bearings, revealing the interplay between an eccentric load and journal bearing speed. The validity of the theoretical algorithm is verified through finite element simulation. The research outcomes hold significant guiding implications for the design and application of internal feedback hydrostatic bearings.

Characterization of rotary valve control vibration system for vibration stress relief applications

To enhance the vibration system characteristic distortion and pressure loss, we propose a novel rotary valve control vibration system. The paper presents the designed structural composition and generation mechanism of the rotary valve control vibration system. It also derives the mathematical model for the rotary valve distribution process and the overall system. The flow field inside the rotary valve is dynamically simulated using the multiple reference frame model, allowing for the determination of the change rule of the rotary valve’s output characteristics. An AMESim model was developed to analyze the vibration characteristics of the rotary valve control system. The effects of parameters such as inlet pressure, motor speed, and oil supply pump displacement were investigated. A rotary valve control vibration system experimental bench was constructed to experimentally verify the output characteristics of the rotary valve and the vibration characteristics of the system. The results indicate that the characteristic curve of the designed vibration system closely resembles a sinusoidal wave. Additionally, the rotary valve exhibits low pressure loss, making it more suitable for vibration stress relief applications. By appropriately increasing the inlet pressure and decreasing the motor speed, the vibration characteristics of the system can be improved.

Prediction of PAN oxidation in a gas turbine bearing chamber using coupled chemical kinetics and CFD simulation of lubricant flow

A Computational Fluid Dynamics (CFD) model, using COMSOL 6.1, was developed in this work to simulate the oil temperature distribution within a bearing housing, to provide a means of predicting the most probable zones for PAN oxidation. Three different zones in the radial direction and two distinct zones in the axial direction were specified with different temperature profiles. It was also found that the rotational speed of the rotor and oil outlet pressure can significantly influence the temperature distribution. Oil inlet temperature was the other factor that had a minor impact on the temperature profile. Furthermore, the highest temperatures were observed in the bulk oil in the area surrounding the rotor. A chemical reaction analysis, which was performed using MATLAB R2022a, was performed to estimate the rate of PAN oxidation. According to the final results; higher rotational speeds increase the rate of oxidation. Moreover, a reduction in revolution speed extends the time required to completely consume the original PAN content. These findings were also used to demonstrate where varnish deposits start to form. Multiple temperature zones were used instead of the average temperature to carefully check the mutual relation between the revolution speed and temperature, and accurately calculate the rate of PAN oxidation reaction.

Transient lubrication analysis of journal-thrust coupled bearing considering time-varying loads and thermal-pressure coupled effect

The journal-thrust coupled bearing (abbreviated as JTC bearing) works at the end of the crankshaft in diesel engine, with the function of carrying radial load and prevent axial movement of the crankshaft. The journal part and the thrust part of this special bearing both form the oil film lubrication when subjected to the time-varying loads in axial and radial directions during the working condition. In this work, the JTC bearing in marine diesel engines was analyzed using a transient thermal elastohydrodynamic (TEHD) lubrication model. The thermal and pressure (thermal-pressure) coupled effects were taken into consideration based on the flow, pressure, and thermal continuity conditions between the journal and thrust parts. Moreover, the transient time-varying load was considered in the lubrication analysis to explore the coupled effect under the actual operating conditions. A test rig was built to validate the established transient TEHD lubrication model for the JTC bearing. The thermal-pressure coupled effect between the journal and thrust parts was found to significantly affect the transient lubrication behaviors of the JTC bearing, which cannot be ignored. Also, different boundary conditions were investigated for the influence of the coupled effect on transient lubrication characteristics, including axial clearances, radial clearances, waveforms of radial load, incline angles and inlet oil temperatures. This work could theoretically support the lubrication design of the JTC bearings used in the diesel engine crankshafts.

Effect of chevron-shaped wetting patterns on oil film thickness in cylinder-on-disc contact under starved lubrication or limited lubricant supply

This study addresses the oil starvation problem in roller bearing line contacts and proposes a novel Chevron-shaped wetting/oleophilic pattern on the bearing track to enhance oil replenishment. Validation through optical cylinder-on-disc lubrication film tests reveals the impact of the pattern on inlet oil supply and film thickness. Notably, a Chevron pattern oriented opposite to disc movement significantly increases film thickness. Wetting is more pronounced in oleophilic areas (Chevron pattern), forming an inverted V-shaped "virtual wall" that directs lubricant backflow toward the center and reduces side leakage. A pattern length equal to the bearing track width was found to be more effective compared to smaller sizes, as the oil side ridges are located on the oleophobic and oleophilic boundaries, which capitalizes the wettability step effect more effectively. This research provides a basis for designing oleophobic surfaces with improved anti-wear and anti-friction properties.

Investigation of the leakage in the flow distribution pair of radial piston hydraulic motors through CFD analysis and experiments

The internal leakage of a radial piston motor (RPM) is an unavoidable structural characteristic, and the amount of internal leakage has a critical effect on the volumetric efficiency of the motor. Using the distribution plate as the force body, an equation for the balance between the preload spring force and the hydrodynamic force is analytically derived, the variation range of the clearance of the flow distribution pair (FDP) is determined, and a model for the internal leakage flow of the FDP is developed. Based on computational fluid dynamics (CFD) simulations, the effects of the oil film thickness, inlet pressure, motor speed, and oil temperature on the leakage volume are investigated. An efficiency test system for RPMs is built and tests are performed on motor prototypes. The experimental results show that the error between experimental and simulation results decreases gradually with increasing motor speed. When the motor runs at the rated speed, the error is stable within 5%. The experimental results verify the correctness of both the theoretical and CFD models. The CFD analysis method can be used as a technical means to optimize the motor volumetric efficiency and the preload spring design.

Effects of Oil and Solid Body Temperatures on Elastohydrodynamic Lubrication Film Formation

The present study focuses on investigating the influence of oil and solid body temperatures on elastohydrodynamic lubrication (EHL) film formation. Experimental and numerical simulation methods are employed to examine three heating methods: oil and ball heating, disc heating, and entire system heating. A preliminary comparison between the measured results and numerical simulations confirms the impact of heating methods on film formation while validating the availability of the numerical models. Further numerical analysis reveals that in the case of oil and ball heating, the temperature gradient induced by differences in solid body temperatures plays a more significant role in film formation compared to the conventional thermal-viscosity wedge effect caused by EHL film shear. This effect is further amplified at large sliding–rolling ratios and in steel–steel contacts. The overall film formation is primarily governed by the oil inlet temperature, whereas local film formation characterized by a dimple shape is influenced by both thermal gradient effects and thermal-viscosity wedge effects. This study provides valuable insights for selecting appropriate heating methods in experiments as well as understanding how temperature differences affect film formation in practical engineering.

Study on Oil Supply Characteristics of Connecting Rod Small End Bearing With Splash Lubrication by Smooth Particle Hydrodynamics Method

Abstract The lubricating oil distribution significantly impacts the lubrication and cooling of the connecting rod small end bearing during the splash lubrication. This study investigates the oil supply for the small end bearing with splash lubrication utilizing the smoothed-particle hydrodynamics. The oil distribution and inlet volume are analyzed under various engine speeds. The results reveal that the oil moves close to the piston surface and hardly enters the oil bores, resulting in oil wastage. The oil entering the bores might be thrown out due to the inertia, causing the oil inlet volume to fluctuate. With increasing engine speeds, the total oil inlet volume under the quasi-steady-state gradually diminishes, exacerbating the lubrication conditions.

An original methodology to model stationary and transient starvation in EHL contact

Abstract Despite many researches in the past decades, starvation modelling of an ElastoHydrodynamic Lubricated (EHL) contact is still an arduous task. The well established Jackobson, Floberg and Olsson (JFO) theory indeed shows jumps discontinuities that are tricky to consider in a numerical solver. Two strategies are discussed in this paper. The first one uses a penalty method while the second one uses a moving mesh method. Their efficiency are compared to reference cases coming from the literature. Then, they are submitted to a transient analysis where the oil inlet layer decreases suddenly.

Design of Jet Control Device for Forced Lubrication System of Bearing

In response to the problem of poor lubrication effect and unstable bearing operation leading to bearing failure in traditional bearings, the solution of installing a jet device on the bearing has been proposed. Using numerical calculation software, analyze the impact of installing a semi-circular or 1/4 circular jet device on the temperature field and leakage rate of the bearing. The results show that after installing a jet control device, the temperature of the flow field around the bearing decreases significantly at the same inlet pressure, while the leakage rate decreases. Keeping the speed and oil temperature constant, as the pressure at the lubricating oil inlet increases, the leakage rate decreases by 51.87% -59.80%; Keeping the rotational speed and oil inlet pressure unchanged, as the temperature of the lubricating oil at the inlet increases, the leakage decreases by 45.94% -50.74%; Keeping the inlet pressure and oil temperature unchanged, when the speed increases, the leakage decreases by 12.58% -18.31%. Install a jet device on the end face of the bearing to achieve collaborative design of low leakage and low temperature rise at the bearing, thus providing a theoretical basis for the long-term design of the bearing.

Parameter optimization design of an aero-engine bearing chamber based on active learning Kriging

The air-oil two-phase flow in the aero-engine bearing chamber is highly complex and unsteady. To obtain the mapping relationship between the oil volume fraction in the chamber and the oil inlet flow rate and rotational speed for further design optimization, the air-oil two-phase flows are simulated using the level set method in COMSOL Multiphysics software. To avoid frequent calls to the simulation model during the optimization process, which consumes huge computational costs, the Kriging model is applied to approximate the true response of the computational fluid dynamics (CFD) simulations. The point addition process is assisted by introducing the active learning function EI to enhance the efficiency of constructing the Kriging model. Particle swarm optimization (PSO) is applied to optimize the Kriging-based optimization objective function. With the optimal parameters’ combination, the performance of the oil return in the aero-engine bearing chamber is improved. This study has guiding significance for the lubrication design of the aero-engine bearing chamber.