Numerical Modeling of Mixed Lubrication and Flash Temperature in EHL Elliptical Contacts

Highly loaded ball and rolling element bearings are often required to operate in the mixed elastohydrodynamic lubrication regime in which surface asperity contact occurs simultaneously during the lubrication process. Predicting performance (i.e., pressure, temperature) of components operating in this regime is important as the high asperity contact pressures can significantly reduce the fatigue life of the interacting components. In this study, a deterministic mixed lubrication model was developed to determine the pressure and temperature of mixed lubricated circular and elliptic contacts for measured and simulated surfaces operating under pure rolling and rolling/sliding condition. In this model, we simultaneously solve for lubricant and asperity contact pressures. The model allows investigation of the condition and transition from boundary to full-film lubrication. The variation of contact area and load ratios is examined for various velocities and slide-to-roll ratios. The mixed lubricated model is also used to predict the transient flash temperatures occurring in contacts due to asperity contact interactions and friction. In order to significantly reduce the computational efforts associated with surface deformation and temperature calculation, the fast Fourier transform algorithm is implemented.