A Novel Optimization Strategy of Bearing Geometry with a Length to Diameter Ratio of 1.25 under Severe Operating Conditions Using Taguchi Method

Robust and well-designed rotor-bearing systems ensure safe operation and a high level of reliability under severe operating conditions. A deviation in the shaft axis with respect to the bearing longitudinal axis represents one of the most unavoidable problems in bearing systems. This deviation results from installation errors, manufacturing errors, shaft deformation under heavy loads, bearing wear, and many other causes. Each of these deviation sources has its negative consequences on the designed characteristics of the system. This work deals with the geometrical design of a journal bearing using three forms of profiles (linear (n=1), quadratic n=2 and cubic (n=3) profiles) in order to enhance bearing performance despite the presence of the inevitable shaft deviation. In addition, a wide range of bearing profile parameters are considered in the analysis to optimize the bearing profile based on the use of the Taguchi method. A general form of shaft deviation is considered to account for both horizontal and vertical deviations. A numerical solution is obtained using the finite difference method. The results show that all three suggested forms of bearing profiles elevate the film thickness significantly and also reduce the friction coefficient, but with different effects on the maximum pressure values. The Taguchi method illustrates that the optimal geometrical design parameters are the quadratic profile and the modification of one-fifth of the bearing width from both sides at a height of just less than half the radial clearance (0.4 C) at the bearing edges. These values give the best combination of the considered main bearing characteristics: the minimum film thickness, coefficient of friction, and maximum pressure. The results show that the minimum film thickness is increased by 184%, the maximum pressure is reduced by 15.1% and the friction coefficient is decreased by 6.4% due to the use of the suggested design. The outcome of this work represents an important enhancement step for the rotor bearing performance to work safely with high reliability under severe shaft deviation levels. This can be implied at the design stage of the bearing, which requires prior knowledge about the operating conditions in order to have better estimation for the levels of shaft deviation.