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Research Papers: Elastohydrodynamic Lubrication

Plasto-Elastohydrodynamic Lubrication in Point Contacts for Surfaces With Three-Dimensional Sinusoidal Waviness and Real Machined Roughness

[+] Author and Article Information
Tao He, Dong Zhu, Jiaxu Wang

School of Aeronautics and Astronautics,
Sichuan University,
Chengdu 610065, China

Ning Ren

Department of Mechanical Engineering,
Northwestern University,
Evanston, IL 60208

1Present address: Ashland, Inc., Lexington, KY 40509.

2Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received October 14, 2013; final manuscript received April 18, 2014; published online May 7, 2014. Assoc. Editor: Xiaolan Ai.

J. Tribol 136(3), 031504 (May 07, 2014) (11 pages) Paper No: TRIB-13-1215; doi: 10.1115/1.4027478 History: Received October 14, 2013; Revised April 18, 2014

Efficiency and durability are among the top concerns in mechanical design to minimize environmental impact and conserve natural resources while fulfilling performance requirements. Today mechanical systems are more compact, lightweight, and transmit more power than ever before, which imposes great challenges to designers. Under the circumstances, some simplified analyses may no longer be satisfactory, and in-depth studies on mixed lubrication characteristics, taking into account the effects of 3D surface roughness and possible plastic deformation, are certainly needed. In this paper, the recently developed plasto-elastohydrodynamic lubrication (PEHL) model is employed, and numerous cases with both sinusoidal waviness and real machined roughness are analyzed. It is observed that plastic deformation may occur due to localized high pressure peaks caused by the rough surface asperity contacts, even though the external load is still considerably below the critical load determined at the onset of plastic deformation in the corresponding smooth surface contact. It is also found, based on a series of cases analyzed, that the roughness height, wavelength, material hardening property, and operating conditions may all have significant influences on the PEHL performance, subsurface von Mises stress field, residual stresses, and plastic strains. Generally, the presence of plastic deformation may significantly reduce some of the pressure spikes and peak values of subsurface stresses and make the load support more evenly distributed among all the rough surface asperities in contact.

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Figures

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Fig. 1

Sketch for calculation of surface plastic deformation

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Fig. 2

Linear hardening law

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Fig. 3

Contact configuration with 3D sinusoidal roughness

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Fig. 4

A sample PEHL solution with sinusoidal surface roughness and its comparison with corresponding EHL solution. W = 80 N, Wc = 91.28 N, Ph = 1.05 GPa, G* = 6567.03181, U* = 0.250564E-12, W* = 0.705252E-07. (a) Pressure comparison, (b) effective plastic strain, (c) EHL subsurface von Mises stress, and (d) PEHL subsurface von Mises stress.

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Fig. 5

Film thickness profile and pressure distribution for the PEHL sample case in Fig. 4. (a) Film thickness profile and (b) pressure distribution.

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Fig. 6

Effects of work hardening property on maximum pressure, von Mises stress, residual stress, effective plastic strain, and average film thickness

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Fig. 7

Effects of rms roughness on maximum pressure, subsurface von Mises stress, residual stress, effective plastic strain, and average film thickness

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Fig. 8

Effects of wavelength on maximum pressure, subsurface von Mises stress, residual stress, and effective plastic strain

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Fig. 9

Effects of rolling speed on maximum pressure, subsurface von Mises stress, residual stress, effective plastic strain, and average film thickness

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Fig. 10

Effects of applied load on maximum pressure, subsurface von Mises stress, residual stress effective plastic strain, and average film thickness

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Fig. 11

A sample PEHL solution with real machined surface and its comparison with EHL solution. W = 80 N, Wc = 91.28 N, Ph = 1.05 GPa, G* = 6567.03181, U* = 0.250564 × 10−12, W* = 0.705252 × 10−7. (a) Pressure comparison, (b) effective plastic strain, (c) EHL subsurface von Mises stress, and (d) PEHL subsurface von Mises stress.

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Fig. 12

Film thickness profile and pressure distribution for the PEHL sample case in Fig. 11. (a) Film thickness profile and (b) pressure distribution.

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Fig. 13

Effects of rolling speed on maximum pressure, subsurface von Mises stress, residual stress, effective plastic strain, and average film thickness

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