Fluid–Structure Interaction Modeling of Elastohydrodynamically Lubricated Line Contacts

Abstract This paper presents a partitioned fluid–structure interaction (FSI) solver to model elastohydrodynamic lubrication (EHL) of line contacts. The FSI model was constructed using the multiphysics simulation software ansys, wherein an iterative implicit coupling scheme is implemented to facilitate the interaction between fluid and solid components. The model uses a finite volume method (FVM) based computational fluid dynamics (CFD) solver to determine the lubricant flow behavior using the Navier–Stokes equations. Additionally, the finite element method (FEM) is utilized to model the structural response of the solid. Fluid cavitation, compressibility, non-Newtonian lubricant rheology, load balance algorithm, and dynamic meshing were incorporated in the FSI model. The pressure and film thickness results obtained from the model are presented for a wide range of loads, speeds, slide to roll ratios (SRR), surface dent, material properties (elastic plastic), etc. The model presents a detailed understanding of EHL contacts by removing any assumptions relative to the Reynolds equation. It provides the (i) two-dimensional variation of pressure, viscosity, etc., in the fluid and (ii) stress, elastic/plastic strain in the solid, simultaneously. The FSI model is robust, easy to implement, and computationally efficient. It provides an effective approach to solve sophisticated EHL problems. The FSI model was used to investigate the effects of surface dents, plasticity and material inclusions under heavily loaded lubricated line contacts as can be found in gears and rolling element bearings. The results from the model exhibit excellent corroboration with published results based on the Reynolds equation solvers.