A fully coupled finite element solution for the mixed elastohydrodynamic lubrication of finite line contacts.

A fully coupled FE model for mixed EHL of finite line contacts is proposed, integrating all of the governing equations into a monolithic system. The solution reveals the fully coupled model achieves 5% higher accuracy and 50% greater efficiency compared to the weakly coupled one. Additionally, there is evidence to support the assertion that profiling contributes to the mitigation of surface roughness contact. Logarithmic profiling can increase the minimum film thickness by a factor of 30, resulting in a reduction of up to 64.6% in the maximum asperity contact pressure, and thus, the boundary friction force is decreased by more than 19%, under heavy-load low-velocity condition. This contributes to the reduction of abrasive wear. • A fully coupled FE model for the mixed EHL analysis of finite line contacts is developed. • Lubrication of mixed EHL film with straight, dub-off, and log profiles under different loads and velocities is analysed. • Influences of profiling on asperity contact and friction force are discussed and revealed. • A logarithmic profile has the potential to enhance the boundary lubrication condition at the free-end. [ABSTRACT FROM AUTHOR]