Feasibility and optimization of a bush-cut aluminium bronze big end bearing: a simulation-based study

The big end bearing of a connecting rod is one of the most highly loaded bearings in marine engines. This paper presents a feasibility study and optimization of the geometrical parameters of a bush-cut bronze bearing for connecting rods in large-bore marine engines. An accurate simulation workflow was developed and carried out in Abaqus to analyze whether a new simple and cost-saving alternative for manufacturing big end bearings would be possible. The simulations showed that aluminium bronze is feasible regarding stress and yielding. However, improvements were needed to increase the radial contact pressure and decrease the compressive tangential stress peaks on the ends of the split bearing. The optimized design parameters included the outer diameter and thickness of the bearing, the thickness of the cutting blade, and the cut angle. Especially the combination of optimized blade thickness and cut angle generated promising results. The findings of this study provide valuable insights and design principles for bearing design processes.