Under mixed lubrication, when there is direct rough contact between two contact surfaces, surface wear occurs, altering surface morphology, which in turn changes their lubrication state. The tribological performance of materials can be improved with in-depth understanding of the coupling mechanism linking surface wear and lubrication. A numerical model was established to predict the lubrication state and wear characteristics of the surface wear process based on non-Gaussian surface reconstruction technology and a mixed elastohydrodynamic lubrication sliding wear model. The evolution of wear characteristics in Gaussian and non-Gaussian rough surfaces was investigated, and the effect of surface skewness and kurtosis on lubrication and wear characteristics was discussed. The results indicated that as the wear cycle increases, the contact area and contact load ratios of the rough surfaces decrease before gradually stabilizing, while the coefficient of friction and maximum flash temperature rise and then gradually decrease. Increasing surface skewness and kurtosis increases the probability of wear, leading to increased accumulated wear, friction coefficient, and maximum flash temperature rise.

The transient lubrication conditions of rolling bearings are different in gearboxes and bearing testers. It has been observed that samples of qualified rolling bearings tested in rolling bearing testers often fail and do not meet lifespan requirements when employed in other lubrication conditions. This may be caused by different factors affecting the bearing in testing and applying lubrication. Needle roller bearings were selected for this study to investigate the causes of this phenomenon in terms of lubrication. Based on the computational fluid dynamics (CFD) method, fluid domain models for the same type of rolling bearings with different lubrication conditions were established. The transient flow fields of rolling bearings with oil jet lubrication in a tester and splash lubrication in a planetary gearbox were simulated. The air–oil transient distribution of rolling bearings in two kinds of lubrication was analyzed. The results indicate that the rotational speed significantly affected the oil jet lubrication of the needle roller bearing. The average oil volume fraction rose by 0.2 with the increase in the bearing speed from 1200 r/min to 6000 r/min and by 0.06 with the increase in the oil jet velocity from 8 m/s to 16 m/s. The splash lubrication of the bearings in the planetary gearbox was directly related to the immersion depth of the rolling bearings in the initial position. Meanwhile, the splash lubrication of the bearings was also affected by other factors, including the initial layout of the planetary gears. The increase in speed from 1200 r/min to 6000 r/min made the average oil volume fraction of splash lubrication decrease by 4.4%. The average oil volume fraction of the bearings with splash lubrication was better than that with oil jet lubrication by an average of 41.9% when the bearing speed was in the low-speed stage, ranging from 1200 r/min to 3600 r/min. On the contrary, the bearings with oil jet lubrication were better than those with splash lubrication by an average of 31.8% when the bearing speed was in the high-speed stage, ranging from 4800 r/min to 6000 r/min.

The relative sliding at the meshing point directly affects the contact and lubrication characteristics of the gear pair and is an important factor of gear wear and power loss. In this study, for investigation of a new type of low sliding ratio (LSR) gear pair whose tooth profile is constructed by a cubic function, a three-dimensional (3D) mixed elastohydrodynamic lubrication (EHL) line contact model was established with consideration of the effect of tooth profile geometry, transient motion characteristics, load distribution, and machining roughness. The distribution of the center film thickness of the LSR gear along the meshing line was predicted through an example the result of which was compared with a typical line contact EHL formula to verify the model. In addition, the difference was investigated in film thickness distribution of friction coefficient and temperature rise between LSR spur gears and involute spur gears. Hence, the effect of 3D rough tooth surface on the contact lubrication characteristics of LSR gears was discussed. The results demonstrated that the minimum center film thickness of the LSR gear appeared at the alternating point of the concave and convex tooth surfaces. At the same time, compared with the involute gear, the LSR gear significantly increased the film thickness at the start and ending points of the meshing and reduced the friction coefficient and the flash temperature rise.

A machined surface has observable fractal characteristics, with infinite local and overall self-similar consistency. Therefore, the fractal theory is considered to provide a better description of the morphological characteristics of rough surfaces, which accurately reflects the randomness and multi-scale characteristics of rough surfaces and it is not comparable with the surface characteristics obtained based on statistical parameters limited by sampling length and device resolution. In this study, the Weierstrass-Mandelbrot (W-M) function was applied to construct a fractal reconstruction surface, and the mixed elastohydrodynamic lubrication model was used to investigate the lubrication characteristics of real and reconstructed surfaces under the same fractal parameters. The effects of the fractal parameters on the fractal surface lubrication characteristics were further analyzed. The results demonstrate that the lateral roughness fractal surface provides greater resistance to the entrained flow of lubricant, which leads to a larger average film thickness, than the longitudinal roughness and isotropic fractal surface. With the increase in fractal dimension, the surface roughness peak density increases, which reduces the surface film thickness by 47%, and the friction coefficient increases by 46%. The lubrication parameter fluctuates slightly with the change in the number of overlapping ridges M of the fractal surface. Generally, M has little effect on the surface lubrication characteristics.

A design method of low sliding ratio face gear drive is presented. The rack and gear meshing pair with a low sliding ratio is obtained by constructing the contact path. The face gear is then formed by this gear, and its tooth width characteristics are analyzed. Combined with the explicit solution of the meshing point of the tooth surface, a method to solve the sliding ratio of the proposed face gear pair is given, and the effects of relevant design parameters on the sliding ratio are analyzed. Moreover, the rationality of the tooth profile design is verified by 3D modeling and motion simulation. The proposed face gear pair has a lower sliding ratio, as well as larger tooth width, than those of traditional face gear drive (the pinion is involute spur gear) with the same basic parameters. The results of this study can provide points of reference for reducing friction and improving the mechanical efficiency of face gear drives.