A Digital Engineering Framework for Piston Pin Bearings via Multi-Physics Thermo-Elasto-Hydrodynamic Modeling

The piston pin operates under severe mechanical and thermal conditions, making accurate lubrication prediction essential for engine durability. This study presents a comprehensive digital engineering framework for piston pin bearings, built upon a fully coupled thermo-elasto-hydrodynamic (TEHD) formulation. The framework integrates: (1) a Reynolds-equation hydrodynamic solver with temperature-/pressure-dependent viscosity and cavitation; (2) elastic deformation obtained from FEA (finite element analysis)-based compliance matrices; (3) a break-in module that iteratively adjusts surface profiles before steady-state simulation; (4) a three-body heat transfer model resolving heat conduction, convection, and solid–liquid interfacial heat exchange. Applied to a heavy-duty diesel engine, the framework reproduces experimentally observed behaviors, including bottom-edge rounding at the small end and the slow unidirectional drift of the floating pin. By integrating multi-physics modeling with design-level flexibility, this work aims to provide a robust digital twin for the piston-pin system, enabling virtual diagnostics, early-stage failure prediction, and data-driven design optimization for engine development.