An elastohydrodynamic analysis of a rotary lip seal is performed numerically, incorporating both the fluid mechanics of the lubricating film and the elastic deformation of the lip, by solving the Reynolds equation with flow factors. Asperities on the lip surface dominate the behavior of the flow field in the lubricating film and the elastic deformation of the lip. Since previous analyses treated those asperities deterministically, they required very large computation times. The present approach is much less computationally intensive because the asperities are treated statistically. Since cavitation and asperity orientation play important roles, these are taken into account in the computation of the flow factors. An asperity distortion analysis is introduced to obtain a more realistic model of the complex variations in the asperity distribution on the surface of the seal. Results of the analysis show how the operating parameters of the seal and the characteristics of the asperities affect such seal characteristics as the thickness of the lubricating film, reverse pumping rate, power dissipation and load carrying capacity.

Journal bearings are being used in various locations of an internal combustion engine. They contribute to a large portion of total engine friction and lowering it means a significant contribution to CO2 reduction. Operating under heavy loads, journal bearings are often subject to mixed regime of lubrication where a part of bearing load is carried by asperities. This necessitates accurate modelling of asperities contact in order to get more realistic predication of friction losses in journal bearings contact. The evaluation method at Scania couples 3D confocal measurement of bearings’ surface roughness to a Multi-body Dynamic Analysis of journal bearings lubrication utilizing AVL EXCITE. During running-in, asperity peaks are reduced due to wear caused by metal-to-metal contact resulting in change of bearing surface profile and different contact zones in axial and circumferential direction. The aim of this thesis is to include these different contact zones and run-in wear profile of the bearing to the existing evaluation method at Scania to simulate run-in effects more precisely. Surface measurements were made on a run-in big end bearing surface at edges, center and region after oil hole. From these measurements, using the existing Local Scale Model at Scania, asperity pressure curve and flow factors were obtained, which were used to perform AVL EXCITE big end bearing simulations with multiple surface contact patches. The results show that the inclusion of multiple surface patches and run-in wear profile lead to a significant change in distribution and also magnitude of bearing performance parameters e.g. pressure, friction losses, clearance height. / Glidlager är en av de mest använda komponenterna i motorer. De bidrar till en stor del av motorns totala friktion och en minskning av denna bidrar i hög grad till minskade utsläpp av CO2. Glidlager som arbetar under hög last utsätts ofta för blandfilmssmörjning där en del av lasten bärs av mekanisk kontakt mellan ytornas asperiteter. Detta kräver en noggrann modellering av asperitetskontakter för att få en realistisk prediktion av friktionsförluster i glidlager.Utvärderingsmetoden på Scania kopplar ihop 3D-mätning av lagrets ytfinhet i ett konfokalmikroskåp med en dynamisk tribologiberäkning i MBS-programvaran (Multi Body Simulation) AVL Excite.Under inkörning nöts asperiteterna ner på grund av metallkontakten mellan ytorna vilket påverkar lagerytans profil och ger olika kontaktzoner i axiell och periferiell riktning.Syftet med examensarbetet är att inkludera de olika kontaktzonerna och lagrets profil efter inkörning i Scanias befintliga utvärderingsmetod i syfte att noggrannare kunna simulera inkörning av lagren.Ytfinhetsmätningar utfördes med ett konfoklamikroskop på ett inkört vevlager vid kanterna, i mitten och i närheten av oljehålet.Med hjälp av dessa mätningar och en av Scanias befintliga kontaktmodeller beräknades asperitetstryck och flödesfaktorer vilka användes för att utföra vevlagerberäkningar i AVL Excite med olika kontaktegenskaper i olika regioner.Resultaten visar att införandet av regioner på lagerytan med olika lokala kontaktegenskaper och lagerprofil efter inkörning ger en signifikant förändring av såväl storleken som fördelningen av olika lagerresultat såsom till exempel lagertryck, friktionsförluster och oljefilmstjocklek.

This master’s thesis introduces a slide bearing analysis using the MBS software tool of FEV Virtual Engine, including real surface topography based on 3D roughness measurements. The first half of the thesis gives a brief overview about gasoline combustion engines, slide bearing usage in engines, slide bearing construction and about essential approaches for the characterization of elasto-hydrodynamic behavior. In the second half, the process of model building, rough surface measurement and preparation of analyses are described. At the end of this thesis, the results of the analyses are shown and discussed.