A multiscale-approach for wear prediction in journal bearing systems – from wearing-in towards steady-state wear

The present study aims to predict the wear in journal bearings during steady-state operation in the mixed-lubrication regime starting with a critical assessment of commonly used wear laws. A novel numerical method is introduced that calculates journal bearing wear on macroscopic and asperity contact scale. For validation of the numerical method, the friction and wear behavior was studied on a special test-rig for journal bearings. Both experimental and numerical results show an initial period of high friction and wear. After the first minutes of operation reduced friction can be observed. The simulations clarify, that this is caused by bearing wear on asperity roughness scale. By considering the reduced asperity interaction due to wearing-in in the calculation of contact conditions a higher accuracy of wear prediction is achieved. •Method to efficiently predict wear in journal bearings.•Effects of wear on macroscopic scale and asperity contact scale are presented.•Critical assessment of linear wear laws during the running-in phase.