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Plain bearings in heavy-duty applications

This page provides an insight into the world of heavy-duty plain bearings. You will find explanations on how the design and construction of the plain bearing materials, understanding how these allow for exceptionally high loads in demanding industrial environments. It explores the materials and construction behind these bearings—such as self-lubricating composites and high-performance plastics—and how their self-lubricating properties enable maintenance-free operation even in harsh conditions.

This page also identifies typical applications, such as construction, agriculture and machinery, and with the help of test results, can provide guidance on selecting the correct bearing solution for long service life and reliable performance

Overview of the test results

In comparison: lubricated metal bearings and self-lubricating igutex® plain bearings

Force/load:
80 MPa (12.8 t on a plain bearing with Ø 40 mm, length 40 mm)

Speed:
0.01 m/s (30 cycles 50°/min.)

shaft:
42 CroMo4+QT gas nitrocarburised with post-oxidation

Cycles:
50,000 = 1.75 km running performance

Test rig with metal mechanism and pressure gauge for a load or function test.

Steel bearing 16MnCr5, hardened

  • Lubricated every 4 hours (unloaded condition)
  • Breakage after approx. 10,000 cycles
  • Massive shaft wear
Shaft and steel bearing in test.

Bronze bearing

  • Lubricated every 4 hours (unloaded condition)
  • Breakage after approx. 10,000 cycles
  • Massive bearing wear
Shaft and bronze bearing in test.

Metal-polymer bearing

  • Lubricated every 4 hours (unloaded condition)
  • 50,000 cycles achieved
  • Massive bearing and shaft wear
Shaft and metal-polymer bearing in test.

igus igutex TX1 plain bearing

  • Tested in dry operation
  • 50,000 cycles achieved
  • Low wear
  • Best result in the test
Shaft and igutex TX1 fibre composite bearing in test.

iglidur® and igutex® plain bearings in the wear test with different loads

Diagram shows wear in µm/km of plain bearings at 45 MPa for two materials and iglidur.

At 45MPa, both iglidur and igutex return low wear results.

Diagram of plain bearing wear at 75 MPa with three materials and comparison values.

At 75MPa, depending on the shaft used, iglidur Q3E is also a viable alternative to igutex.

Diagram of plain bearing wear at 100 MPa with three compared material groups.

At a load of 100MPa, igutex® TX3 exhibits the lowest wear by far.

Different lubrication methods: Advantages and requirements

Lubrication-free

Lubrication-free bearing point with a cylindrical component.

Requirements

  • Corrosion-protected shaft/receptacle required
  • Depending on the operating conditions, a seal may be useful to protect the system from massive ingress of dirt.

igus advantages

  • Longer service life
  • No failure due to insufficient lubrication
  • Lower shaft quality requirements
  • Lower price
  • No maintenance required
  • No lubrication system required (lubrication holes, grooves, cable, grease gun, centralised lubrication)
  • No grease discharge into the environment

Initial lubrication

Bearing point with initial lubrication in section.

The grease is for the mount and shaft. The bearing does not need it!

Requirements

  • Effort for one-off lubrication of shaft and mount during assembly
  • A seal is useful to ensure that the grease applied once remains in the system for the duration of operation

igus advantages

  • Longer service life
  • No failure due to insufficient lubrication
  • Lower shaft quality requirements
  • Lower price
  • No maintenance effort
  • (Almost) no grease discharge into the environment

Regular lubrication

Bearing position with regular lubrication on a shaft.

The grease is for the mount and shaft. The bearing does not need it!

Requirements

  • Effort for lubrication
  • Complete lubrication system (lubrication holes, grooves, cable, grease gun, centralised lubrication)
  • Regular maintenance schedule (provision of lubricant, personnel)

igus advantages

  • Longer service life
  • No failure due to insufficient lubrication
  • Lower shaft quality requirements
  • Lower price
  • Reduced maintenance costs possible due to extended intervals

Our materials for lubrication-free heavy-duty applications

iglidur® Materials are manufactured by injection moulding or machined from extruded bar stock. Choose from over 8,500 catalogue parts or have your desired design manufactured according to your specifications. In addition to the iglidur® materials for harsh environments, there are also variants for high temperatures, particularly long service lives and other areas of application.

Materials for use under high loads
igutex® fibre composite plain bearings have been specially developed and optimised for use under extreme loads. Due to the flexibility of the winding technology, large diameters can also be manufactured.

Composite plain bearing sleeve.

igutex® TX1- The robust all-rounder

  • Temperature [°C] +120
  • surface pressure [MPa] 200
  • coefficient of friction [µ] 0,37
  • wear [µm/km] 7
More about igutex TX1
igutex TX2 fibre composite bearings

igutex® TX2 -The specialist for hard shafts

  • Temperature [°C] +130
  • surface pressure [MPa] 180
  • coefficient of friction [µ] 0,31
  • wear [µm/km] 7
More about igutex TX2
igus TX3 plain bearing made of igutex material.

igutex® TX3 -The endurance runner for the highest loads

  • Temperature [°C] +130
  • surface pressure [MPa] 180
  • coefficient of friction [µ] 0,28
  • wear [µm/km] 2
More about igutex TX3
iglidur q3e plain bearing ring.

iglidur® Q3E- 2 component high load bearing

  • Temperature [°C] +100
  • surface pressure [MPa] 135
  • coefficient of friction [µ] 0,56
  • wear [µm/km] 2,1
More about iglidur Q3E

Whitepapers and fact sheets

Our white papers and factsheets provide you with information on a wide range of topics, such as protection against corrosion, dirt and sealing, mounting methods for plain bearings or locating spigots.

Brochure on lubrication-free bearing points with an igus cover and open pages about bearing materials.

lubrication-free bearing points in construction machinery

The white paper covers the following topics, among others:

  • Important functions of lubrication in plain bearings
  • Reasons for switching to lubrication-free plain bearings
  • Differentiation: lubrication-free iglidur® plain bearings vs. lubricated metallic bearings
  • Functionality of self-lubricating plain bearings
  • What to consider when switching to dry-running plain bearings
Download now for free (PDF)
iglidur Heavy Duty brochure with cover and open inner pages about industrial solutions.

Heavy Duty brochure

Find out more about the following topics:

  • Material overview of heavy-duty plain bearings
  • How iglidur® and igutex® materials work
  • lubrication - a challenge for the industry
  • Sustainable product development
  • Application examples from practice
Download now for free (PDF)
igus factsheet on gas nitrocarburizing with corrosion protection tests and comparison results.

Factsheet - Gas nitrocarburising

How well does gas nitrocarburising protect shafts against corrosion? In the test, various shaft materials in combination with iglidur® plain bearings and igutex® fibre composite plain bearings were subjected to a salt spray test. All test results can be found in the factsheet.

Download the factsheet
Factsheet on corrosion protection wax with test results for wear and force.

Factsheet - avoid reduced interference fit

The use of anti-corrosion agents can reduce the interference fit of your plain bearings. We have therefore tested various anti-corrosion agents. You can find out which agents almost double the interference fit by downloading this factsheet.

Request the factsheet
Factsheet on axial locking for cylindrical plain bearings, with four illustrated variants.

Factsheet - locating spigot for sleeve bearing

You have various options for locating spigots for sleeve bearings. In this factsheet, you can find out what these are and what you need to bear in mind when securing them.

Download the factsheet

Factsheet - Sealing concepts with felt

Find out why materials such as felt is suitable for sealing bearing points. This factsheet also contains important design information on plain bearings with felt seal.

igus factsheet on the sealing concept with felt, with a diagram and notes on use and design.
Download the factsheet

Factsheet - Mounting igutex® plain bearings

Here you can find out everything you need to know about mounting our igutex® fibre composite plain bearings.


igutex mounting factsheet for plain bearings with press-fit, freezing, and heating instructions.
Download the factsheet

References

Kässbohrer Geländefahrzeug AG

In the chassis of its tracked vehicles, Kässbohrer Geländefahrzeug AG uses igutex® fibre composite bearings that function reliably even in dirt.

More about the application
Tracked vehicle with a work arm lifts a platform in the snow in front of a forest.

Demarko

Demarko uses igutex® fibre composite bearings in oscillating axles for semi-trailers. The bearings are part of the igus® standard range and require no additional lubrication.

More about the application
Vehicle wheel with a dusty tyre sidewall on a utility vehicle.

Ship & Yacht Engineering Ltd.

The Ship & Yacht Engineering Ltd. stern gallows is suitable for a swivel load of up to 20 tons and uses igutex plain bearings in the swivel kinematics because they also work in weather and salt water.

More about the application
A-frame crane lifts heavy ship parts in the harbour.

Thaler GmbH & Co. KG

iglidur plain bearings can also be found in Thaler GmbH & Co. KG farm loaders, where they are used because the bearing points are resistant to dirt and require little maintenance.

More about the application
Thaler loader with front attachment on the yard.

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