Surface irregularities substantially affect the performance of tribological systems. The influence of three-dimensional surface irregularities has been investigated on the behavior of hole-entry spherical hybrid journal bearings. Recently, smart fluids have been employed in several applications to improve their performance. The interactive effect of electro-rheological (ER) fluid and surface irregularities have also been studied. The modified Reynolds equation and restrictor flow equation have been solved using the finite element technique with appropriate boundary conditions. The results show that consideration of surface irregularities on bearing surface enhances bearing stability. Spherical hybrid journal bearings lubricated by ER fluid increase minimum fluid film thickness and minimize the possibility of metal-to-metal contact. It is found that the combined effect of surface irregularities and ER fluid significantly improved the bearing performance parameters than individual behavior. The bearing designer is anticipated to benefit from the current model.

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