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Machine components are designed to endure increasingly severe operating conditions due to the strive for improved energy efficiency of mechanical systems. Consequently, lubricated non-conformal contacts must rely on thin lubricant films where the influence of surface topography on the lubricating conditions becomes significant. Due to the complexity of the multiphysical problem, approximate assumptions are often employed to facilitate numerical studies of elastohydrodynamically lubricated (EHL) contacts. In this work, the rough, time dependent, thermal EHL problem is solved with focus on two main analyses. The first analysis focuses on the influence of sinusoidal roughness and the difference between a thermal non-Newtonian approach and an isothermal Newtonian approach. The second analysis is focused on the lubricating mechanisms taking place when two-sided surface features overtake within the thermal EHL contact. The results indicate that the film thickness in the outlet of the contact may be significantly overestimated by an isothermal Newtonian approach and that differences in the high-pressure region may also occur due to viscosity variations in the inlet of the contact. Moreover, for the studied two-sided surface features, it became evident that not only the surface feature combination but also the overtaking position influence the film thickness and pressure variations significantly.

On Waviness and Two-Sided Surface Features in Thermal Elastohydrodynamically Lubricated Line Contacts