Margarita Mármol Fernández, Lukas Rüth, Bernd Sauer

• In some specific applications, the need of an optimized rolling bearing, having a similar load carrying capacity as a tapered roller bearing but with much lower friction losses is still to be addressed. In this paper, a new model is developed using a multibody simulation software and its experimental validation is presented. After studying many different (in use and only patented) roller geometries and based on an existing and already validated model for tapered roller bearings, a new model has been created changing the basis of its geometry. When the rolling bearing is highly loaded, the new geometry will show lower friction losses than a conventional tapered roller bearing. In order to confirm this premise, as well as to validate the model, a prototype of the new optimized geometry has been manufactured and experimentally tested, together with a tapered roller bearing of same main dimensions. The tests have taken place in a frictional torque test rig, where it is possible to realistically reproduce the loads and misalignments occurring on a bearing. The results of these tests together with its comparisons with the results of the multibody simulation models are discussed here. It has been observed, that the new model not only can be validated, but also presents less friction losses than the ones obtained when using a tapered roller bearing under some operating points with highly loaded bearings.