| Preface |
|
xiii | |
| Nomenclature |
|
xvii | |
| About the Companion Website |
|
xxv | |
|
|
|
1 | (124) |
|
1 Elastohydrodynamic Lubrication (EHL) |
|
|
3 | (56) |
|
|
|
3 | (4) |
|
1.2 Governing Equations in Dimensional Form |
|
|
7 | (21) |
|
1.2.1 Generalized Reynolds Equation |
|
|
9 | (6) |
|
1.2.2 Film Thickness Equation |
|
|
15 | (3) |
|
1.2.3 Linear Elasticity Equations |
|
|
18 | (6) |
|
1.2.4 Load Balance Equation |
|
|
24 | (1) |
|
|
|
24 | (4) |
|
1.2.6 Shear Stress Equations |
|
|
28 | (1) |
|
1.3 Governing Equations in Dimensionless Form |
|
|
28 | (8) |
|
1.3.1 Dimensionless Parameters |
|
|
29 | (2) |
|
1.3.2 Generalized Reynolds Equation |
|
|
31 | (1) |
|
1.3.3 Film Thickness Equation |
|
|
32 | (1) |
|
1.3.4 Linear Elasticity Equations |
|
|
33 | (1) |
|
1.3.5 Load Balance Equation |
|
|
34 | (1) |
|
|
|
34 | (2) |
|
1.3.7 Shear Stress Equations |
|
|
36 | (1) |
|
1.4 Lubricant Constitutive Behavior |
|
|
36 | (8) |
|
1.4.1 Pressure and Temperature Dependence |
|
|
37 | (1) |
|
|
|
37 | (2) |
|
|
|
39 | (2) |
|
1.4.1.3 Thermal Conductivity and Heat Capacity |
|
|
41 | (1) |
|
1.4.2 Shear Dependence of Viscosity |
|
|
41 | (2) |
|
1.4.3 Limiting Shear Stress (LSS) |
|
|
43 | (1) |
|
|
|
44 | (2) |
|
1.6 Review of EHL Numerical Modeling Techniques |
|
|
46 | (6) |
|
|
|
52 | (7) |
|
|
|
52 | (7) |
|
2 Finite Element Method (FEM) |
|
|
59 | (66) |
|
|
|
59 | (2) |
|
2.2 Model Partial Differential Equation (PDE) |
|
|
61 | (2) |
|
2.3 Steady-State Linear FEM Analysis |
|
|
63 | (36) |
|
2.3.1 Elementary Integral Formulations |
|
|
64 | (1) |
|
2.3.1.1 Weighted-Residual Form |
|
|
64 | (1) |
|
|
|
65 | (1) |
|
2.3.2 Solution Approximation |
|
|
66 | (1) |
|
2.3.2.1 Meshing and Discretization |
|
|
67 | (2) |
|
2.3.2.2 Lagrange Linear Elements |
|
|
69 | (4) |
|
2.3.2.3 Lagrange Quadratic Elements |
|
|
73 | (2) |
|
2.3.3 Galerkin Formulation |
|
|
75 | (3) |
|
2.3.4 Integral Evaluations: Mapping between Reference and Actual Elements |
|
|
78 | (7) |
|
2.3.5 Connectivity of Elements |
|
|
85 | (1) |
|
2.3.6 Assembly Process and Treatment of Boundary Conditions |
|
|
86 | (4) |
|
|
|
90 | (1) |
|
2.3.8 Post-Processing of the Solution |
|
|
91 | (1) |
|
2.3.9 One-Dimensional Example |
|
|
92 | (7) |
|
2.4 Steady-State Nonlinear FEM Analysis |
|
|
99 | (10) |
|
2.4.1 Newton Methods for Nonlinear Systems of Equations |
|
|
99 | (1) |
|
|
|
100 | (2) |
|
2.4.1.2 Damped-Newton Method |
|
|
102 | (3) |
|
2.4.2 Nonlinear FEM Formulation |
|
|
105 | (4) |
|
2.5 Transient FEM Analysis |
|
|
109 | (3) |
|
2.5.1 Space-Time Discretization |
|
|
110 | (1) |
|
2.5.2 Time-Dependent FEM Formulation |
|
|
111 | (1) |
|
2.6 Multi-Physical FEM Analysis |
|
|
112 | (6) |
|
2.6.1 Multi-Physical FEM Formulation |
|
|
113 | (2) |
|
|
|
115 | (1) |
|
2.6.3 Coupling Strategies |
|
|
116 | (1) |
|
|
|
217 | (1) |
|
2.6.3.2 Full/Strong Coupling |
|
|
117 | (1) |
|
2.7 Stabilized FEM Formulations |
|
|
118 | (5) |
|
2.7.1 Isotropic Diffusion (ID) |
|
|
120 | (1) |
|
2.7.2 Streamline Upwind Petrov--Galerkin (SUPG) |
|
|
121 | (1) |
|
2.7.3 Galerkin Least Squares (GLS) |
|
|
121 | (2) |
|
|
|
123 | (2) |
|
|
|
123 | (2) |
|
Part II Finite Element Modeling Techniques |
|
|
125 | (214) |
|
3 Steady-State Isothermal Newtonian Line Contacts |
|
|
127 | (38) |
|
3.1 Contact Configuration |
|
|
127 | (1) |
|
3.2 Geometry, Computational Domains, and Meshing |
|
|
128 | (4) |
|
|
|
128 | (1) |
|
3.2.2 Computational Domains |
|
|
128 | (2) |
|
3.2.3 Meshing and Discretization |
|
|
130 | (2) |
|
3.3 Governing Equations and Boundary Conditions |
|
|
132 | (6) |
|
|
|
133 | (3) |
|
3.3.2 Linear Elasticity Equations |
|
|
136 | (2) |
|
3.3.3 Load Balance Equation |
|
|
138 | (1) |
|
|
|
138 | (12) |
|
3.4.1 Connectivity of Elements |
|
|
139 | (1) |
|
3.4.2 Weak Form Formulation |
|
|
139 | (2) |
|
3.4.3 Elementary Matrix Formulations |
|
|
141 | (1) |
|
|
|
142 | (2) |
|
3.4.3.2 Hydrodynamic Part |
|
|
144 | (1) |
|
3.4.3.3 Load Balance Part |
|
|
145 | (1) |
|
3.4.4 Stabilized Formulations |
|
|
146 | (4) |
|
3.5 Overall Solution Procedure |
|
|
150 | (3) |
|
3.6 Model Calibration and Preliminary Results |
|
|
153 | (8) |
|
3.6.1 Mesh Sensitivity Analysis |
|
|
153 | (1) |
|
3.6.2 Penalty Term Tuning |
|
|
153 | (3) |
|
3.6.3 Solid Domain Size Calibration |
|
|
156 | (1) |
|
3.6.4 Preliminary Results |
|
|
157 | (4) |
|
|
|
161 | (4) |
|
|
|
161 | (4) |
|
4 Steady-State Isothermal Newtonian Point Contacts |
|
|
165 | (34) |
|
4.1 Contact Configuration |
|
|
165 | (1) |
|
4.2 Geometry, Computational Domains, and Meshing |
|
|
166 | (4) |
|
|
|
166 | (1) |
|
4.2.2 Computational Domains |
|
|
166 | (3) |
|
4.2.3 Meshing and Discretization |
|
|
169 | (1) |
|
4.3 Governing Equations and Boundary Conditions |
|
|
170 | (105) |
|
|
|
171 | (2) |
|
4.3.2 Linear Elasticity Equations |
|
|
173 | (1) |
|
4.3.3 Load Balance Equation |
|
|
174 | (1) |
|
|
|
175 | (1) |
|
4.4.1 Connectivity of Elements |
|
|
175 | (1) |
|
4.4.2 Weak Form Formulation |
|
|
176 | (1) |
|
4.4.3 Elementary Matrix Formulations |
|
|
177 | (1) |
|
|
|
178 | (2) |
|
4.4.3.2 Hydrodynamic Part |
|
|
180 | (2) |
|
4.4.3.3 Load Balance Part |
|
|
182 | (1) |
|
4.4.4 Stabilized Formulations |
|
|
183 | (4) |
|
4.5 Overall Solution Procedure |
|
|
187 | (3) |
|
4.6 Model Calibration and Preliminary Results |
|
|
190 | (6) |
|
4.6.1 Mesh Sensitivity Analysis |
|
|
190 | (1) |
|
4.6.2 Penalty Term Tuning |
|
|
191 | (1) |
|
4.6.3 Preliminary Results |
|
|
192 | (4) |
|
|
|
196 | (3) |
|
|
|
196 | (3) |
|
5 Steady-State Thermal Non-Newtonian Line Contacts |
|
|
199 | (44) |
|
5.1 Contact Configuration |
|
|
199 | (1) |
|
5.2 Geometry, Computational Domains, and Meshing |
|
|
200 | (3) |
|
|
|
200 | (1) |
|
5.2.2 Computational Domains |
|
|
200 | (1) |
|
5.2.3 Meshing and Discretization |
|
|
201 | (2) |
|
5.3 Governing Equations and Boundary Conditions |
|
|
203 | (5) |
|
5.3.1 Generalized Reynolds Equation |
|
|
204 | (1) |
|
5.3.2 Linear Elasticity Equations |
|
|
205 | (1) |
|
5.3.3 Load Balance Equation |
|
|
205 | (1) |
|
|
|
205 | (2) |
|
5.3.5 Shear Stress Equation |
|
|
207 | (1) |
|
|
|
208 | (19) |
|
5.4.1 Connectivity of Elements |
|
|
208 | (2) |
|
5.4.2 Weak Form Formulation |
|
|
210 | (3) |
|
5.4.3 Elementary Matrix Formulations |
|
|
213 | (2) |
|
|
|
215 | (1) |
|
5.4.3.2 Hydrodynamic Part |
|
|
215 | (3) |
|
5.4.3.3 Load Balance Part |
|
|
218 | (1) |
|
|
|
219 | (5) |
|
5.4.3.5 Shear Stress Part |
|
|
224 | (1) |
|
5.4.4 Stabilized Formulations |
|
|
225 | (2) |
|
5.5 Overall Solution Procedure |
|
|
227 | (1) |
|
5.6 Model Calibration and Preliminary Results |
|
|
228 | (12) |
|
5.6.1 Mesh Sensitivity Analysis |
|
|
230 | (1) |
|
5.6.2 Full versus Weak Coupling |
|
|
230 | (9) |
|
5.6.3 Preliminary Results |
|
|
239 | (1) |
|
|
|
240 | (3) |
|
|
|
241 | (2) |
|
6 Steady-State Thermal Non-Newtonian Point Contacts |
|
|
243 | (38) |
|
6.1 Contact Configuration |
|
|
243 | (1) |
|
6.2 Geometry, Computational Domains, and Meshing |
|
|
244 | (3) |
|
|
|
244 | (1) |
|
6.2.2 Computational Domains |
|
|
244 | (1) |
|
6.2.3 Meshing and Discretization |
|
|
245 | (2) |
|
6.3 Governing Equations and Boundary Conditions |
|
|
247 | (5) |
|
6.3.1 Generalized Reynolds Equation |
|
|
248 | (1) |
|
6.3.2 Linear Elasticity Equations |
|
|
249 | (1) |
|
6.3.3 Load Balance Equation |
|
|
249 | (1) |
|
|
|
249 | (3) |
|
6.3.5 Shear Stress Equations |
|
|
252 | (1) |
|
|
|
252 | (22) |
|
6.4.1 Connectivity of Elements |
|
|
253 | (2) |
|
6.4.2 Weak Form Formulation |
|
|
255 | (3) |
|
6.4.3 Elementary Matrix Formulations |
|
|
258 | (2) |
|
|
|
260 | (1) |
|
6.4.3.2 Hydrodynamic Part |
|
|
261 | (3) |
|
6.4.3.3 Load Balance Part |
|
|
264 | (1) |
|
|
|
264 | (6) |
|
6.4.3.5 Shear Stress Part |
|
|
270 | (3) |
|
6.4.4 Stabilized Formulations |
|
|
273 | (1) |
|
6.5 Overall Solution Procedure |
|
|
274 | (1) |
|
6.6 Model Calibration and Preliminary Results |
|
|
275 | (5) |
|
6.6.1 Mesh Sensitivity Analysis |
|
|
276 | (1) |
|
6.6.2 Preliminary Results |
|
|
276 | (4) |
|
|
|
280 | (1) |
|
|
|
280 | (1) |
|
|
|
281 | (1) |
|
7.1 Contact Configuration |
|
|
281 | (1) |
|
7.2 Geometry, Computational Domains, and Meshing |
|
|
281 | (1) |
|
73 Governing Equations, Boundary, and Initial Conditions |
|
|
282 | (15) |
|
|
|
282 | (2) |
|
7.3.2 Linear Elasticity Equations |
|
|
284 | (1) |
|
7.3.3 Load Balance Equation |
|
|
284 | (1) |
|
|
|
284 | (5) |
|
7.4.1 Connectivity of Elements |
|
|
285 | (1) |
|
7.4.2 Weak Form Formulation |
|
|
285 | (1) |
|
7.4.3 Elementary Matrix Formulations |
|
|
286 | (2) |
|
|
|
288 | (1) |
|
7.4.3.2 Hydrodynamic Part |
|
|
288 | (1) |
|
7.4.3.3 Load Balance Part |
|
|
289 | (1) |
|
7.5 Overall Solution Procedure |
|
|
289 | (2) |
|
|
|
291 | (4) |
|
|
|
295 | (2) |
|
|
|
295 | (2) |
|
8 Model Order Reduction (MOR) Techniques |
|
|
297 | (42) |
|
|
|
297 | (2) |
|
8.2 Reduced Solution Space Techniques |
|
|
299 | (14) |
|
|
|
302 | (1) |
|
8.2.2 Ritz-Vector-Like Method |
|
|
303 | (1) |
|
8.2.3 EHL-Basis Technique |
|
|
304 | (2) |
|
8.2.3.1 Typical Test Case Results |
|
|
306 | (4) |
|
8.2.3.2 Performance Analysis: Reduced versus Full Model |
|
|
310 | (3) |
|
8.3 Static Condensation with Splitting (SCS) |
|
|
313 | (22) |
|
8.3.1 Static Condensation |
|
|
315 | (1) |
|
|
|
316 | (1) |
|
8.3.3 Overall Numerical Procedure |
|
|
316 | (4) |
|
8.3.4 Results and Discussion |
|
|
320 | (1) |
|
8.3.4.1 Typical Test Cases |
|
|
320 | (1) |
|
8.3.4.2 Splitting Algorithm Tuning |
|
|
321 | (6) |
|
8.3.4.3 Preservation of Solution Scheme Generality |
|
|
327 | (2) |
|
8.3.4.4 Performance Analysis |
|
|
329 | (6) |
|
|
|
335 | (4) |
|
|
|
337 | (2) |
|
|
|
339 | (66) |
|
9 Pressure and Film Thickness Predictions |
|
|
341 | (20) |
|
|
|
341 | (1) |
|
9.2 Qualitative Parametric Analysis |
|
|
341 | (7) |
|
9.2.1 Isothermal Newtonian Conditions |
|
|
342 | (3) |
|
9.2.2 Thermal Non-Newtonian Conditions |
|
|
345 | (3) |
|
9.3 Quantitative Predictions |
|
|
348 | (3) |
|
9.4 Analytical Film Thickness Predictions |
|
|
351 | (6) |
|
9.4.1 Numerical Experiments |
|
|
352 | (1) |
|
9.4.2 Correction Factors and Film Thickness Formulas |
|
|
353 | (2) |
|
9.4.3 Experimental Validation |
|
|
355 | (2) |
|
|
|
357 | (4) |
|
|
|
359 | (2) |
|
|
|
361 | (22) |
|
|
|
361 | (2) |
|
10.2 Quantitative Predictions |
|
|
363 | (6) |
|
|
|
369 | (11) |
|
10.3.1 Relevant Dimensionless Numbers |
|
|
370 | (1) |
|
10.3.1.1 Weissenberg Number |
|
|
370 | (1) |
|
10.3.1.2 Nahme--Griffith Number |
|
|
370 | (1) |
|
10.3.1.3 Limiting Shear Stress Number |
|
|
370 | (1) |
|
10.3.1.4 Roller Compliance Number |
|
|
370 | (1) |
|
10.3.2 Delineation of Friction Regimes |
|
|
371 | (4) |
|
|
|
375 | (1) |
|
10.3.2.2 Nonlinear Viscous Regime |
|
|
376 | (1) |
|
|
|
377 | (1) |
|
10.3.2.4 Thermoviscous Regime |
|
|
378 | (1) |
|
10.3.3 Friction Regimes Chart |
|
|
378 | (2) |
|
|
|
380 | (3) |
|
|
|
381 | (2) |
|
|
|
383 | (22) |
|
|
|
383 | (2) |
|
|
|
385 | (3) |
|
11.3 Influence of Coating Properties on EHL Contact Performance |
|
|
388 | (14) |
|
11.3.1 Pressure and Film Thickness |
|
|
389 | (2) |
|
|
|
391 | (3) |
|
|
|
394 | (1) |
|
11.3.3.1 Influence of Coating Mechanical Properties |
|
|
394 | (2) |
|
11.3.3.2 Influence of Coating Thermal Properties |
|
|
396 | (6) |
|
|
|
402 | (3) |
|
|
|
403 | (2) |
|
|
|
405 | (24) |
|
|
|
407 | (10) |
|
|
|
412 | (1) |
|
|
|
412 | (1) |
|
|
|
413 | (1) |
|
|
|
414 | (1) |
|
|
|
415 | (2) |
|
|
|
417 | (6) |
|
|
|
418 | (1) |
|
B.2 Compressed Row Storage (CRS) |
|
|
419 | (1) |
|
B.3 Compressed Column Storage (CCS) |
|
|
419 | (4) |
|
C Shell T9 Lubricant Properties |
|
|
423 | (6) |
|
C.1 Pressure and Temperature Dependence of Density |
|
|
423 | (1) |
|
C.2 Pressure and Temperature Dependence of Viscosity |
|
|
424 | (1) |
|
C.3 Shear Dependence of Viscosity |
|
|
425 | (1) |
|
C.4 Pressure Dependence of Limiting Shear Stress |
|
|
426 | (1) |
|
C.5 Pressure and Temperature Dependence of Thermal Properties |
|
|
427 | (2) |
| References |
|
429 | (2) |
| Index |
|
431 | |