The surface scuffing occurring in line-contact lubrication is related to the roller’s roughness pattern and asperity height. For surfaces with same contact asperity height, the magnitudes of friction power (Pf = fWVs) relevant to various roughness patterns are found to have the same sequence as the critical local temperatures. Instead of using the nominal contact area, the real contact area (At) is used to obtain the true friction power intensity (Ptfi = Pf/At). A new scuffing failure model (Ptfi · σ−0.317 = C, where σ denote rms roughness) shows that the scuffing resistance of surfaces with transverse roughness pattern is higher than that of surfaces with longitudinal and oblique patterns. For certain roughness patterns, a high root mean square roughness height a is always associated with the high Ptfi value just before scuffing.

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