Enhancing the durability of heavy-duty engines requires a deeper understanding of wear failure mechanisms in critical big-end bearings. The complex interdependencies among tribology, dynamics, and wear behaviors poses challenges for accurate modeling, and the underlying failure mechanisms remain inadequately understood under demanding operating conditions. This study proposes a novel tribo-dynamic-wear coupling model for big-end bearings that integrates mixed lubrication, multi-friction-pair dynamics, and the transient evolution of wear morphology. A full-scale engine experiment is performed to validate the model's accuracy, and a detailed surface failure analysis offers insights into the wear mechanisms under real-world conditions. The findings reveal a clear wear asymmetry between the upper and lower bearing surfaces, with the upper surface experiencing more severe wear. Additionally, an axial wear gradient is observed, with the test wear depth at the central region approximately 9.10 μm greater than at the edges. These distinct wear patterns are successfully predicted by the proposed model. The primary cause of exacerbated wear is identified as a significant reduction in hydrodynamic lubrication, driven by the combined effects of high load and low speed. This results in the highest transient solid contact force ratio (94.72%) among the three representative conditions (1000 rpm, 1400 rpm, and 1800 rpm at 100% load). Another contributing factor is the concurrent occurrence of multiple wear mechanisms, including abrasive, oxidative, adhesive, and mild fatigue wear.

General reductions in lubricant viscosities and increasing loads in machine components highlight the role of tribofilms in providing surface protection against scuffing. However, the relationship between the scuffing process and the growth and removal of tribofilm is not well understood. In this study, a multiphysics coupling model, which includes hydrodynamic lubrication, asperity contact, thermal effect, tribochemistry reaction, friction, and surface wear, was developed to capture the initiation of surface scuffing. Simulations and experiments for a piston ring and cylinder liner contact were conducted following a step-load sequence under different temperature conditions. The results show that high temperature and extreme load could induce the lubricant film collapse, which in turn triggers the breakdown of the tribofilm due to the significantly increased removal process. The failures of both lubricant film and tribofilm progress instantaneously in a coupling way, which finally leads to severe scuffing.

When the oil supply is not adequate to maintain the ideal lubrication, angular contact ball bearing will enter into the starved lubrication regime resulting in the potential performance degradation and consequently the severe failures. To study the effects of starved lubrication on the performance of angular contact ball bearing, this paper first proposes a multi-degree-of-freedom (DOF) tribo-dynamic model by introducing five-DOF inner ring, six-DOF balls, and six-DOF cage. The model considers the starved lubrication in the ball-raceway contact and the full multi-body interactions between the bearing components. With different ball-raceway starvation degrees being analyzed, the effects of starved lubrication on the bearing tribo-dynamic performance are first revealed. By comparison, it is found that the oil film thickness, the skidding performance, and the traction forces in the ball-raceway contact are significantly influenced by the starvation degrees. It is also found that the starvation-induced change of the ball-pocket contact force is dramatical under combined loads, and the maximum contact force under this load condition increases with the increasing starvation degrees.

A crosshead slipper-guide system, which bears a significant thrust force, is an essential friction pair in low-speed marine diesel engines. Owing to the low moving speed of the crosshead slipper during engine startup, it is difficult to form good hydrodynamic lubrication between the crosshead slipper and guide. Therefore, a detailed analysis of the crosshead slipper during engine startup is needed. In this study, a new transient tribo-dynamic model for a crosshead slipper during the engine startup process is presented. The model consists of a mixed lubrication model of the crosshead slipper-guide and dynamic models of the piston assembly, crosshead assembly, connecting rod, and crankshaft. The tribo-dynamic performances of the crosshead slipper during startup and under the rated conditions were simulated and compared. The results show that the tribo-dynamics of the crosshead slipper during the startup process are significantly different from those under the rated conditions. Some measures beneficial for the low friction of a crosshead slipper-guide under the rated conditions may significantly increase the friction loss of the crosshead slipper-guide system during the startup process.

For the ring/liner conjunction, well-designed surface texturing has been regarded as a potential means to improve its tribological performance, as well as the application of coating. However, so far most researchers focused on the one of these aspects. In this study, the combined effect of coating and texturing on the performance of ring/liner conjunction is numerically investigated. A thermal mixed lubrication model is presented. The effects of the coating’s thermal and mechanical properties on the tribological performance are studied under the cold and warm engine operating conditions. Along with the increasing coating thickness, the effects of the coating’s thermal properties on friction loss are found to be significant, as well as the effects of the coating’s mechanical properties. It is also found that a soft coating with a lower thermal inertia has a greater ability to reduce the friction loss of the textured conjunction.