Coupled modelling and analysis of lubrication-wear evolution of textured piston/cylinder pair in high-pressure common rail pumps

Abstract Surface texturing is an important approach to enhance fluid lubrication performance and reduce friction and wear. Research on the surface texturing of the piston/cylinder pair considering various characteristics such as multi-physical fields and the evolution of friction and wear is still insufficient. The novelty of this work aims to establish a coupled numerical simulation model considering the coupling effect of multiple physical fields, wear of the cylinder bore and surface texture, and determine the effective surface texture parameters to improve the friction performance of the mechanical components of high-pressure common rail pump. The influence of surface texture on friction and wear characteristics and the evolution of lubrication-wear under different geometric cases were in-depth investigated, and the action mechanism of surface texture on lubrication and wear was revealed. Through numerical analysis, optimal parameters were identified that significantly reduce the friction coefficient and wear amount, offering practical insights for mitigating friction and wear in mechanical systems.