Topology Optimization of Micro-Textured Interfaces for Enhanced Load-Bearing Capacity: Validation via Interface Enriched Lubrication and Anti-Scuffing Analyses

Current research lacks systematic understanding of cross-scale correlations between micro-texture geometry and macro-lubrication behavior. This study presents a multi-scale collaborative optimization methodology for gear Micro-Textured Meshing Interface (MTMI). An objective function targeting macroscopic interfacial performance is formulated, and a topology optimization strategy is employed to achieve optimal MET configuration. The homogenization analysis captures the modulating effects of MET on local flow and stress fields, while topology optimization transcends conventional parametric geometric constraints, enabling the generation of non-regular MET topological patterns tailored to complex operating conditions, thereby ensuring optimal macroscopic ASLBC. The proposed scheme is validated through numerical simulations of two representative problems capturing distinct lubrication regimes: (1) IEL, characterizing transient load-bearing dynamics governed by temporally evolving MET configurations; and (2) ASLBC, elucidating steady-state load-bearing capacity modulation via spatially heterogeneous MET distributions. A Taylor expansion-based surrogate model is developed to efficiently explore the MET configuration design space, significantly enhancing computational efficiency and solution accuracy for multi-scale optimization. While the gradient-based algorithm cannot guarantee global optimality, extensive numerical simulations and cross-validation studies demonstrate consistent convergence toward high-performance MET configurations, with sensitivity analyses of design parameters further confirming the engineering applicability of the optimized solutions.