Preface |
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xvii | |
Acknowledgments |
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xix | |
Authors |
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xxi | |
Nomenclature |
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xxiii | |
Chapter 1 Introduction |
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1 | (16) |
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1.1 Significance of the Topics |
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1 | (1) |
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1.2 Tribological Interface Systems |
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2 | (8) |
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1.2.1 Interface Systems Defined Based on Geometry |
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2 | (4) |
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1.2.2 Interface Systems Defined Based on Relative Motion |
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6 | (1) |
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1.2.3 Interface Systems Defined Based on Lubricating Media |
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7 | (2) |
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1.2.4 Interface Systems Defined Based on Lubrication Status |
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9 | (1) |
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1.3 Brief Historic Review |
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10 | (5) |
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1.3.1 Empirical Knowledge Accumulated in Early Years |
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10 | (1) |
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11 | (1) |
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1.3.3 Establishment of Contact Mechanics and Lubrication Theory |
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11 | (1) |
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1.3.4 Rapid Development Assisted by Digital Computers |
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12 | (1) |
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1.3.5 Recent Advancements |
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13 | (1) |
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14 | (1) |
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1.4 Interfacial Mechanics |
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15 | (1) |
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1.5 Coverage of This Book |
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15 | (2) |
Chapter 2 Properties of Engineering Materials and Surfaces |
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17 | (16) |
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2.1 Mechanical Properties of Typical Solid Materials |
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17 | (1) |
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2.2 Topographic Properties of Engineering Surfaces |
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18 | (6) |
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2.2.1 Engineering Surfaces |
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18 | (1) |
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2.2.2 Surface Characterization by Statistical Parameters |
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19 | (4) |
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2.2.3 Surface Characterization by Direct Digitization |
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23 | (1) |
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2.2.4 Rough Surfaces Generated by Computer |
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24 | (1) |
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24 | (9) |
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25 | (1) |
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2.3.2 Effect of Temperature on Viscosity |
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25 | (1) |
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2.3.3 Effect of Pressure on Viscosity |
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26 | (2) |
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28 | (1) |
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2.3.5 Non-Newtonian Behaviors |
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28 | (2) |
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2.3.6 Additives in Lubricants |
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30 | (3) |
Chapter 3 Fundamentals of Contact Mechanics |
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33 | (48) |
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33 | (1) |
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3.2 Basic Half-Space Elasticity Theories |
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33 | (7) |
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3.2.1 Potential Equations |
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33 | (2) |
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3.2.2 Displacement Due to Normal Loading |
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35 | (1) |
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3.2.3 Displacement Due to Tangential Traction |
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36 | (2) |
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3.2.4 General Equations for Surface Displacements |
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38 | (1) |
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3.2.5 Subsurface Stresses |
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39 | (1) |
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3.3 Line Contact Hertzian Theory |
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40 | (2) |
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40 | (1) |
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3.3.2 Contact Pressure and Surface Deformation |
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41 | (1) |
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3.3.3 Subsurface Stresses |
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42 | (1) |
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3.4 Point Contact Hertzian Theory |
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42 | (3) |
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42 | (1) |
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3.4.2 Contact Pressure and Surface Deformation |
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43 | (1) |
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3.4.3 Subsurface Stresses |
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44 | (1) |
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3.5 Contact Strength Analysis Based on the Subsurface Stress Field |
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45 | (9) |
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3.5.1 Theories for Yield Criteria |
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45 | (2) |
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3.5.2 Subsurface Stress Field and Yield Pressure in Line Contacts |
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47 | (1) |
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3.5.3 Subsurface Stress Field and Yield Pressure in Circular Contacts |
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48 | (1) |
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3.5.4 Subsurface Stress Field in Elliptical Contacts |
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48 | (2) |
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3.5.5 Effect of Friction on the Subsurface Stresses |
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50 | (2) |
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3.5.6 Contact Yield Initiation in a Case-Hardened Solid |
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52 | (2) |
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52 | (1) |
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3.5.6.2 Solution for Circular Contacts |
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52 | (1) |
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3.5.6.3 Solution for Line Contacts |
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53 | (1) |
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3.5.6.4 General Expressions |
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54 | (1) |
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3.6 Selected Basic Solutions |
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54 | (5) |
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3.6.1 Displacements Due to Concentrated Forces |
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54 | (1) |
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3.6.2 Surface Displacements Induced by Uniform Pressure |
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55 | (1) |
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3.6.2.1 2D Plane Strain Problem |
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55 | (1) |
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3.6.2.2 3D Half-Space Problems |
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56 | (1) |
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3.6.3 Indentation by a Rigid Punch |
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56 | (1) |
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3.6.4 Frictionless Indentation by a Blunt Wedge or Cone |
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57 | (1) |
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3.6.5 A Sinusoidal Wavy Surface in Contact with a Flat |
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57 | (2) |
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57 | (1) |
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58 | (1) |
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3.7 Contact with Rough Surfaces |
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59 | (7) |
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3.7.1 A Stochastic Model for Rough Surface Contacts |
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59 | (2) |
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3.7.2 Empirical Formulae Based on Numerical Solutions for Rough Surface Contacts |
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61 | (5) |
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3.7.2.1 Empirical Formulae by Lee and Ren (1996) |
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61 | (3) |
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3.7.2.2 Empirical Formulae by Chen et al. (2007) |
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64 | (2) |
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3.8 Contact of Multilayer Materials |
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66 | (13) |
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3.8.1 Problem Description |
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66 | (2) |
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3.8.2 Fourier Transforms of the Governing and Boundary/Interfacial Equations |
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68 | (2) |
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3.8.3 Structures of B and AC Matrices |
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70 | (4) |
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3.8.3.1 B Matrix and B Matrix Equation |
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70 | (2) |
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3.8.3.2 AC Matrix and AC Matrix Equation |
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72 | (2) |
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3.8.4 Solutions of Matrix Equations |
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74 | (3) |
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3.8.5 Typical Sample Cases |
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77 | (1) |
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3.8.6 Solution for Problems with a Single-Layer Coating |
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77 | (1) |
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3.8.7 Extended Hertzian Theories |
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78 | (1) |
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79 | (2) |
Chapter 4 Numerical Methods for Solving Contact Problems |
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81 | (42) |
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81 | (3) |
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81 | (1) |
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81 | (1) |
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81 | (1) |
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82 | (1) |
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4.1.5 Quadratic Programming Approach and CGM |
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83 | (1) |
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4.1.6 Fast Fourier Transform (FFT) Approaches |
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83 | (1) |
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4.1.7 Discrete Convolution and Fast Fourier Transform (DC-FFT) Approach |
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83 | (1) |
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4.1.8 Contact Problems with Inelastic and Inhomogeneous Materials |
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84 | (1) |
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4.2 Discretization with Influence Coefficients |
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84 | (9) |
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84 | (1) |
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4.2.2 Influence Coefficients for 2D Half-Plane Problems |
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84 | (3) |
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4.2.2.1 ICs Based on Zero-Order Approximation |
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85 | (1) |
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4.2.2.2 ICs Based on First-Order Approximation |
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86 | (1) |
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4.2.2.3 ICs Based on Second-Order Approximation |
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86 | (1) |
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4.2.3 Influence Coefficients for 3D Half-Space Problems |
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87 | (6) |
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4.2.3.1 ICs Based on Zero-Order Approximation |
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88 | (1) |
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4.2.3.2 ICs Based on Bilinear Approximation |
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88 | (3) |
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4.2.3.3 ICs Based on Biquadratic Approximation |
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91 | (2) |
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4.3 Comparative Cases for Deformation Calculation |
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93 | (2) |
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4.3.1 Deformation Due to Indentation by a Rigid Punch |
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93 | (1) |
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4.3.2 Deformation Due to Cylindrical Contact Hertzian Pressure |
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94 | (1) |
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4.3.3 Deformation Due to Point-Contact Hertzian Pressure |
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95 | (1) |
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4.4 Solution for Contact Pressure Distribution |
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95 | (5) |
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4.4.1 Problem Description |
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95 | (2) |
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4.4.2 Conjugate Gradient Method for Solving Contact Problems |
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97 | (3) |
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100 | (2) |
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4.6 FFT-Based Methods for Efficient Surface Deformation Calculation |
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102 | (15) |
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102 | (1) |
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4.6.2 Three Types of Convolution |
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103 | (1) |
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4.6.3 DC-FFT Algorithm for Non-Periodic Contact Problems |
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104 | (7) |
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4.6.3.1 Cyclic Convolution and the DC-FFT Algorithm |
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104 | (3) |
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4.6.3.2 DC-FFT Procedure for Point Contacts |
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107 | (1) |
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4.6.3.3 Method Comparisons |
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108 | (2) |
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4.6.3.4 Numerical Examples |
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110 | (1) |
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4.6.4 Continuous Convolution and Fourier Transform (CC-FT) and FRF-IC Conversion |
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111 | (3) |
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4.6.4.1 Description of the CC-FT Approach |
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111 | (2) |
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4.6.4.2 Validation and Sample Cases |
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113 | (1) |
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4.6.5 DCD-FFT, DC-CC-FFT, and DCS-FFT Approaches |
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114 | (3) |
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4.6.5.1 General Description |
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114 | (1) |
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4.6.5.2 DCD-FFT Algorithm |
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114 | (1) |
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4.6.5.3 DC-CC-FFT Algorithm |
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115 | (1) |
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4.6.5.4 DCS-FFT Algorithm |
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115 | (2) |
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4.7 Calculation of Subsurface Stresses |
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117 | (4) |
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117 | (1) |
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4.7.2 Influence Coefficients |
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118 | (1) |
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4.7.3 DC-FFT Approach for Stress Calculation |
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119 | (1) |
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4.7.4 Additional Numerical Examples |
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120 | (1) |
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121 | (2) |
Chapter 5 Fundamentals of Hydrodynamic Lubrication |
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123 | (30) |
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123 | (1) |
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123 | (16) |
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5.2.1 Derivation of Generalized Reynolds Equation |
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124 | (3) |
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5.2.2 Simplified Reynolds Equations |
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127 | (2) |
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5.2.3 Boundary Conditions for the Reynolds Equation |
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129 | (1) |
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5.2.4 Reynolds Equation for Non-Newtonian Lubricants |
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130 | (3) |
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5.2.5 Average Reynolds Equation |
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133 | (6) |
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139 | (4) |
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5.3.1 Energy Equation for the Lubricant Film |
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139 | (2) |
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5.3.2 Heat Transfer Equations for Contacting Bodies |
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141 | (1) |
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5.3.3 Surface Temperature Equations |
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141 | (2) |
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5.4 Analytical Solutions for Simplified Bearing Problems |
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143 | (7) |
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5.4.1 General Description |
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143 | (1) |
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5.4.2 Infinitely Long Journal Bearings |
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144 | (3) |
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5.4.3 Infinitely Short Journal Bearings |
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147 | (1) |
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5.4.4 Infinitely Long Thrust Bearings |
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148 | (2) |
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150 | (3) |
Chapter 6 Numerical Methods for Hydrodynamic Lubrication |
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153 | (30) |
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6.1 Finite Length Journal Bearings |
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153 | (9) |
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6.1.1 Finite Difference Method (FDM) |
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153 | (6) |
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6.1.2 Finite Element Method (FEM) |
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159 | (3) |
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6.2 Mixed Thermal Elastohydrodynamic Lubrication (TEHL) Analyses for Journal Bearings |
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162 | (8) |
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162 | (1) |
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6.2.2 Hydrodynamic Lubrication Model Considering Roughness Effect |
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163 | (1) |
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6.2.3 Asperity Contact Models |
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164 | (1) |
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6.2.4 Evaluation of Body Deformations |
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165 | (1) |
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166 | (1) |
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6.2.6 Numerical Procedure |
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167 | (1) |
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6.2.7 Typical Sample Results |
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168 | (2) |
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6.3 Piston Skirts in Mixed Lubrication |
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170 | (11) |
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171 | (1) |
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6.3.2 Average Reynolds Equation |
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172 | (2) |
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6.3.3 Wavy Surface Contact Pressure |
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174 | (1) |
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6.3.4 Deformations of Piston Skirts and Cylinder Bore |
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175 | (2) |
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6.3.5 Numerical Procedure |
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177 | (1) |
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6.3.6 Typical Sample Results |
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178 | (3) |
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181 | (2) |
Chapter 7 Lubrication in Counterformal Contacts-Elastohydrodynamic Lubrication (EHL) |
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183 | (68) |
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183 | (1) |
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7.2 Background and Early Studies |
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183 | (14) |
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7.2.1 Martin"s Theory (Isoviscous-Rigid) |
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183 | (2) |
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7.2.2 Blok"s Theory (Piezoviscous-Rigid) |
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185 | (1) |
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7.2.3 Herrebrugh"s Solution (Isoviscous-Elastic) |
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186 | (1) |
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7.2.4 Grubin"s Inlet Analysis (Piezoviscous-Elastic) |
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186 | (1) |
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7.2.5 First Full EHL Solution in Line Contacts by Petrusevich (1951) |
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187 | (1) |
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7.2.6 Full EHL Solution in Line Contacts by Dowson-Higginson (1959) |
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188 | (1) |
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7.2.7 First Full EHL Solution in Point Contacts by Ranger et al. (1975) |
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189 | (4) |
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7.2.8 Full EHL Solution in Point Contacts by Hamrock and Dowson (1976-1977) |
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193 | (2) |
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7.2.9 Dimensionless Parameter Groups |
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195 | (1) |
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7.2.10 Maps of Lubrication Regimes |
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196 | (1) |
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7.3 EHL Numerical Solution Methods |
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197 | (28) |
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7.3.1 Nonlinearity of EHL Equation Systems |
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197 | (1) |
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7.3.2 Straightforward Iterative Method |
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198 | (1) |
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199 | (1) |
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7.3.4 System Analysis through the Newton-Raphson Procedure |
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199 | (3) |
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202 | (3) |
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7.3.6 Coupled Differential Deflection Method |
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205 | (1) |
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7.3.7 Semi-System Approach |
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205 | (5) |
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205 | (1) |
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7.3.7.2 Basic Formulation |
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206 | (1) |
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7.3.7.3 Discretization of the Pressure Flow Terms |
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206 | (1) |
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7.3.7.4 Discretization of the Entraining Flow Term |
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207 | (1) |
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7.3.7.5 Characteristics of the Coefficient Matrix |
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208 | (1) |
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7.3.7.6 Sample Mixed EHL Solutions from the Semi-System Approach |
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209 | (1) |
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7.3.8 Simulation of Contact by Using the EHL Equation System |
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210 | (3) |
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7.3.9 Effect of Differential Schemes |
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213 | (6) |
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213 | (1) |
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7.3.9.2 Differential Schemes for the Combined Entraining Flow Term |
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214 | (1) |
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7.3.9.3 Differential Schemes for the Separate Entraining Flow Terms |
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215 | (1) |
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7.3.9.4 Effect of Differential Scheme Arrangement |
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216 | (1) |
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7.3.9.5 Schemes for the Further Separated Entraining Flow Term |
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217 | (2) |
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7.3.9.6 Differential Schemes for the Squeeze Flow Term |
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219 | (1) |
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7.3.10 Effect of Mesh Density |
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219 | (5) |
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219 | (1) |
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7.3.10.2 Dependence of Film Thickness Solution on Mesh Density |
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220 | (2) |
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7.3.10.3 Reasonable Mesh Density to be Used in Practice |
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222 | (1) |
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7.3.10.4 Limitations of the MG Approach |
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222 | (2) |
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7.3.11 Progressive Mesh Densification (PMD) Method |
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224 | (1) |
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7.4 Experimental Validation of Numerical Solution |
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225 | (2) |
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7.5 EHL with Arbitrary Entrainment Angle |
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227 | (5) |
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227 | (1) |
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7.5.2 Formulation and Numerical Method |
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227 | (1) |
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7.5.3 Typical Results for Validating the Model and Showing the Basic Characteristics |
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228 | (2) |
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7.5.4 Curve-Fitting Formula |
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230 | (1) |
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7.5.5 Transition of Lubrication Condition with Roughness Considered |
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231 | (1) |
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7.6 Treatments for Starvation and Cavitation |
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232 | (8) |
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232 | (1) |
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7.6.2 Conventional Treatment |
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233 | (2) |
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7.6.2.1 Review of Early Studies |
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233 | (1) |
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7.6.2.2 Reexamination of the Empirical Formulae |
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234 | (1) |
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235 | (1) |
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7.6.3 Updated Treatment Based on JFO and Elrod |
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235 | (5) |
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7.6.3.1 Basic Concept and Formulation |
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235 | (1) |
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7.6.3.2 Numerical Solution Method |
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236 | (1) |
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7.6.3.3 Typical Sample Solutions |
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237 | (1) |
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7.6.3.4 Comparison with Conventional Treatment |
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238 | (2) |
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7.7 Isothermal EHL Behaviors with Smooth Surfaces |
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240 | (9) |
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240 | (1) |
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7.7.2 Entraining Speed Effect |
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241 | (3) |
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244 | (2) |
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7.7.4 Effect of Contact Ellipticity |
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246 | (1) |
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7.7.5 Effect of Materials Properties |
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247 | (4) |
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7.7.5.1 Effect of Different Viscosity Models |
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247 | (1) |
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7.7.5.2 Effect of Lubricant Piezoviscous Property |
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248 | (1) |
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7.7.5.3 Effect of Elastic Property of Solids |
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249 | (1) |
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249 | (2) |
Chapter 8 Mixed Lubrication with Rough Surfaces |
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251 | (48) |
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251 | (4) |
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251 | (1) |
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8.1.2 Review of Stochastic Models |
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251 | (1) |
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8.1.3 Review of Deterministic Models |
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252 | (1) |
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8.1.4 Review of Combined Stochastic-Deterministic Approach |
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253 | (1) |
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254 | (1) |
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255 | (4) |
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8.3 Deterministic Approach for Artificial Roughness |
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259 | (7) |
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259 | (1) |
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8.3.2 Calculation Methods for Derivatives al-flaX and aillaX |
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260 | (1) |
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261 | (1) |
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8.3.4 Sample Validation Cases |
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262 | (4) |
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8.4 Deterministic Approach for Machined Roughness |
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266 | (5) |
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8.4.1 Problem Description |
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266 | (1) |
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8.4.2 Two Ways to Calculate partialdifferentialS/partialdifferentialX and partialdifferentialS/partialdifferentialT |
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266 | (1) |
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8.4.3 Accuracy Comparison Between Methods I+D and D+I |
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267 | (2) |
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8.4.4 Sample Rough Surface EHL Solutions |
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269 | (2) |
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8.5 Stability of Transient Solution |
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271 | (4) |
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8.5.1 Contribution to Coefficient Matrix by Squeeze Flow Term |
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271 | (1) |
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8.5.2 Initial Value Problem |
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272 | (2) |
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8.5.3 Effect of Time Step Length Employed |
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274 | (1) |
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8.5.4 Effect of Convergence Accuracy Requirement |
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275 | (1) |
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8.6 Three-Dimensional Infinitely Long Line Contact-Mixed EHL Solution |
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275 | (5) |
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275 | (1) |
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276 | (1) |
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8.6.3 Sample Cases with Smooth Surfaces for Model Verification |
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277 | (2) |
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8.6.4 Sample Cases with Machined Surface Roughness |
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279 | (1) |
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8.7 Three-Dimensional Finite Roller Contact Mixed EHL Solution |
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280 | (3) |
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280 | (1) |
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8.7.2 Roller Contact Geometry |
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280 | (1) |
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8.7.3 Typical Sample Cases |
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281 | (1) |
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8.7.4 Simulation of Lubrication Transition with Roughness |
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282 | (1) |
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8.8 Basic Mixed EHL Characteristics |
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283 | (8) |
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283 | (2) |
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8.8.2 Limitations of Stochastic Mixed Lubrication Models |
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285 | (1) |
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8.8.3 Rough Surface Mixed EHL Model Validation |
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286 | (2) |
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8.8.4 Transition Characterized by A. Ratio |
|
|
288 | (3) |
|
8.8.5 Effect of Roughness Height on the Mixed EHL Behaviors |
|
|
291 | (1) |
|
8.9 Effect of Roughness Orientation on Film Thickness |
|
|
291 | (5) |
|
|
291 | (2) |
|
8.9.2 Case Study with Machined Roughness |
|
|
293 | (1) |
|
8.9.3 Case Study with Sinusoidal Wavy Surfaces |
|
|
294 | (2) |
|
|
296 | (3) |
Chapter 9 Thermal Behaviors at Counterformal Contact Interfaces |
|
299 | (46) |
|
|
299 | (2) |
|
9.2 Flash Temperature Calculation |
|
|
301 | (11) |
|
|
301 | (1) |
|
9.2.2 Point Heat Source Integration Method |
|
|
302 | (5) |
|
9.2.2.1 Influence Coefficient Algorithm |
|
|
302 | (1) |
|
9.2.2.2 Calculation of Influence Coefficients |
|
|
303 | (2) |
|
9.2.2.3 Three Ways to Carry Out Summation Operations |
|
|
305 | (1) |
|
9.2.2.4 Comparative Study via. Numerical Examples |
|
|
305 | (2) |
|
9.2.3 Simplified Approach for Cases at High Peclet Numbers |
|
|
307 | (5) |
|
9.3 Full TEHL Solution with Smooth Surfaces |
|
|
312 | (14) |
|
9.3.1 Line Contact TEHL Solutions |
|
|
312 | (4) |
|
9.3.1.1 Basic Equations for Line Contact TEHL Problems |
|
|
313 | (2) |
|
9.3.1.2 Brief Description of Numerical Method |
|
|
315 | (1) |
|
9.3.1.3 Typical Line Contact TEHL Results |
|
|
316 | (1) |
|
9.3.2 Point Contact TEHL Solution |
|
|
316 | (10) |
|
9.3.2.1 Basic TEHL Equations for Point Contact Problems |
|
|
316 | (2) |
|
9.3.2.2 Solution Domains and Initial/Boundary Conditions |
|
|
318 | (1) |
|
9.3.2.3 Numerical Solution Methods |
|
|
318 | (4) |
|
9.3.2.4 Sample Results and Discussions |
|
|
322 | (4) |
|
9.4 Full Solution of Mixed TEHL with Rough Surfaces |
|
|
326 | (13) |
|
9.4.1 Mixed TEHL Model Description |
|
|
326 | (2) |
|
|
328 | (3) |
|
|
331 | (1) |
|
9.4.4 Basic TEHL Characteristics |
|
|
332 | (3) |
|
9.4.5 TEHL with Surface Roughness |
|
|
335 | (1) |
|
9.4.6 Transition from Boundary and Mixed to Full-Film Lubrication |
|
|
336 | (2) |
|
9.4.7 Effect of Lubricant Non-Newtonian Behaviors |
|
|
338 | (1) |
|
9.5 Thermal Reduction of EHL Film Thickness |
|
|
339 | (2) |
|
|
341 | (2) |
|
|
343 | (2) |
Chapter 10 Behaviors of Interfacial Friction |
|
345 | (32) |
|
|
345 | (4) |
|
10.1.1 Importance of the Topic |
|
|
345 | (1) |
|
10.1.2 Brief Review of Early Studies |
|
|
345 | (1) |
|
10.1.3 Friction in Full-Film EHL |
|
|
346 | (1) |
|
10.1.4 Friction in Mixed Lubrication |
|
|
347 | (1) |
|
10.1.5 Development of the Stribeck Curves |
|
|
347 | (2) |
|
10.2 Dry Contact Friction |
|
|
349 | (5) |
|
|
349 | (1) |
|
10.2.2 Classic Laws of Friction |
|
|
350 | (1) |
|
10.2.3 Mechanisms of Friction |
|
|
351 | (2) |
|
10.2.4 Summary to Classic Friction Theories |
|
|
353 | (1) |
|
10.3 Boundary Lubrication Friction |
|
|
354 | (5) |
|
10.3.1 General Description |
|
|
354 | (2) |
|
10.3.2 Formation of Adsorption Film |
|
|
356 | (1) |
|
10.3.3 Effect of Boundary Additives on Lubrication Performance |
|
|
356 | (3) |
|
|
359 | (2) |
|
10.5 Friction in Lubricated Conformal Contacts |
|
|
361 | (1) |
|
10.6 Friction in Lubricated Counterformal Contacts (EHL Friction) |
|
|
362 | (3) |
|
|
362 | (1) |
|
10.6.2 Basic Characteristics of EHL Friction |
|
|
362 | (1) |
|
10.6.3 Rheological Models |
|
|
363 | (1) |
|
10.6.4 Calculation of EHL Friction |
|
|
364 | (1) |
|
10.6.5 Sample Calculation Results |
|
|
364 | (1) |
|
10.7 Friction in Mixed Lubrication |
|
|
365 | (5) |
|
|
365 | (1) |
|
10.7.2 Mixed Lubrication Friction in Conformal Contacts |
|
|
366 | (1) |
|
10.7.3 Mixed Lubrication Friction in Counterformal Contacts |
|
|
367 | (1) |
|
10.7.4 Friction Reduction in Mixed Lubrication |
|
|
368 | (2) |
|
|
370 | (5) |
|
10.8.1 Calculation of the Stribeck Curves |
|
|
370 | (1) |
|
10.8.2 Test Apparatus for the Stribeck Curve Measurements |
|
|
371 | (1) |
|
10.8.3 Sample Stribeck Curves Measured |
|
|
371 | (1) |
|
10.8.4 Comparison between Measured and Calculated Stribeck Curves |
|
|
372 | (3) |
|
10.9 More Friction Reduction Technologies |
|
|
375 | (1) |
|
|
375 | (2) |
Chapter 11 Contact of Elastoplastic and Inhomogeneous Materials |
|
377 | (38) |
|
|
377 | (1) |
|
11.2 Fundamentals of Plasticity Theory |
|
|
377 | (5) |
|
11.2.1 Plasticity of Materials |
|
|
377 | (2) |
|
|
377 | (1) |
|
|
378 | (1) |
|
11.2.2 Strain Hardening and Plastic Flow |
|
|
379 | (3) |
|
11.2.2.1 Yield Initiation and Strain Hardening |
|
|
379 | (1) |
|
11.2.2.2 Elastic-Perfectly Plastic (EPP) Behavior |
|
|
380 | (1) |
|
11.2.2.3 Isotropic Hardening Rule |
|
|
380 | (1) |
|
11.2.2.4 Kinematic Hardening Rule |
|
|
380 | (1) |
|
11.2.2.5 Combined Isotropic and Kinematic Hardening Rule |
|
|
381 | (1) |
|
11.2.2.6 Plastic Strain Increment |
|
|
381 | (1) |
|
11.3 Elastoplastic Contact Modeling |
|
|
382 | (5) |
|
|
382 | (1) |
|
11.3.1.1 Elasto-Perfectly Plastic Contact Analysis through the FEM |
|
|
382 | (1) |
|
11.3.1.2 FEM Simulations Considering Strain Hardening |
|
|
383 | (1) |
|
11.3.2 Semi-Analytical Method |
|
|
383 | (4) |
|
|
383 | (1) |
|
11.3.2.2 Description of the Approach by Jacq et al. |
|
|
384 | (2) |
|
11.3.2.3 Typical Examples for a Repeated Rolling/Sliding Contact |
|
|
386 | (1) |
|
11.4 Inclusion and Equivalent Inclusion Method (EIM) |
|
|
387 | (4) |
|
11.4.1 Inclusion and Eigenstrain |
|
|
388 | (1) |
|
11.4.2 Inhomogeneity and EIM |
|
|
389 | (1) |
|
11.4.3 Elastic Fields Caused by Eigenstrains |
|
|
390 | (1) |
|
11.5 Core Solutions to Eigenstrain-Induced Elastic Fields |
|
|
391 | (9) |
|
|
391 | (1) |
|
11.5.2 General Description |
|
|
391 | (2) |
|
|
393 | (1) |
|
11.5.4 Stress Field Outside C2 |
|
|
394 | (3) |
|
11.5.5 Stress Field Inside SI |
|
|
397 | (1) |
|
11.5.6 Surface Displacement |
|
|
397 | (1) |
|
11.5.7 Uniform Unit Eigenstrain in a Cuboid and Related Influence Coefficients |
|
|
398 | (2) |
|
11.5.8 Discrete Correlation and Fast Fourier Transform (DCR-FFT) |
|
|
400 | (1) |
|
11.6 Numerical EIM by S. B. Liu et al. (2012) and Related Improvements |
|
|
400 | (13) |
|
11.6.1 General Formulation and Numerical Procedure for Contact Problems |
|
|
401 | (1) |
|
11.6.2 Traction Cancellation Method (TCM) |
|
|
402 | (1) |
|
11.6.3 Other Enhancement Methods |
|
|
403 | (2) |
|
11.6.4 Numerical Examples |
|
|
405 | (8) |
|
11.6.4.1 Stresses Due to a Single Inhomogeneity |
|
|
405 | (2) |
|
11.6.4.2 Surface Coating as an Inhomogeneity |
|
|
407 | (1) |
|
11.6.4.3 Composites with Distributed Particles |
|
|
408 | (2) |
|
11.6.4.4 Matrix Material Yield Strength/Hardness |
|
|
410 | (1) |
|
11.6.4.5 Double Inhomogeneities |
|
|
411 | (2) |
|
11.6.4.6 Rolling Contact Fatigue of Composite Materials |
|
|
413 | (1) |
|
11.7 Unified Contact Modeling and Advantages of the SAM |
|
|
413 | (1) |
|
11.7.1 Unified Framework for Contact Modeling |
|
|
413 | (1) |
|
11.7.2 SAM with Numerical EIM |
|
|
414 | (1) |
|
|
414 | (1) |
Chapter 12 Plasto-Elastohydrodynamic Lubrication (PEHL) |
|
415 | (36) |
|
|
415 | (2) |
|
12.1.1 Importance of the Topic |
|
|
415 | (1) |
|
12.1.2 Brief Review of the Available Studies |
|
|
416 | (1) |
|
|
417 | (3) |
|
12.2.1 Problem Description |
|
|
417 | (1) |
|
12.2.2 Basic Mixed PEHL Equations |
|
|
417 | (3) |
|
12.3 Numerical Procedure for Solving the PEHL Problems |
|
|
420 | (1) |
|
12.4 Smooth Surface PEHL Simulations |
|
|
420 | (6) |
|
12.4.1 PEHL Model Validation |
|
|
420 | (2) |
|
|
422 | (1) |
|
12.4.3 Smooth Surface PEHL Under an Increasing Load |
|
|
423 | (2) |
|
12.4.4 Effect of Work-Hardening Property |
|
|
425 | (1) |
|
12.5 Rough Surface PEHL Simulations |
|
|
426 | (12) |
|
12.5.1 PEHL with a Single Surface Asperity |
|
|
426 | (4) |
|
12.5.1.1 Basic PEHL Phenomena with a Stationary Asperity |
|
|
426 | (2) |
|
12.5.1.2 Effects of Asperity Height and Radius |
|
|
428 | (1) |
|
12.5.1.3 PEHL Phenomena with a Moving Surface Asperity |
|
|
429 | (1) |
|
12.5.2 PEHL with a Single Surface Dent |
|
|
430 | (3) |
|
12.5.2.1 Basic PEHL Phenomena with a Stationary Dent |
|
|
431 | (1) |
|
12.5.2.2 Effects of Dent Depth and Radius |
|
|
432 | (1) |
|
12.5.2.3 PEHL Phenomena with a Moving Surface Dent |
|
|
432 | (1) |
|
12.5.3 PEHL with Sinusoidal Surfaces |
|
|
433 | (4) |
|
12.5.3.1 Basic PEHL Characteristics and Comparison with EHL Results |
|
|
433 | (2) |
|
12.5.3.2 Effect of Material-Hardening Property |
|
|
435 | (1) |
|
12.5.3.3 Effects of Rough Surface Geometric Parameters |
|
|
435 | (1) |
|
12.5.3.4 Effects of Operating Conditions |
|
|
436 | (1) |
|
12.5.4 PEHL with Real Machined Rough Surfaces |
|
|
437 | (1) |
|
12.6 PEHL in Line Contacts of Both Infinite and Finite Lengths |
|
|
438 | (3) |
|
|
438 | (1) |
|
12.6.2 Smooth Surface PEHL Solutions |
|
|
438 | (2) |
|
12.6.3 Rough Surface Mixed PEHL Solutions |
|
|
440 | (1) |
|
12.7 PEHL in a Rolling Contact |
|
|
441 | (7) |
|
12.7.1 Basic Model for PEHL in a Rolling Contact |
|
|
441 | (2) |
|
12.7.2 Numerical Procedure |
|
|
443 | (1) |
|
12.7.3 Results and Discussions |
|
|
444 | (8) |
|
12.7.3.1 PEHL Results for the First Rolling Cycle |
|
|
444 | (1) |
|
12.7.3.2 PEHL Results for the Second Rolling Cycle |
|
|
445 | (1) |
|
12.7.3.3 Ratcheting and Shakedown |
|
|
445 | (1) |
|
12.7.3.4 PEHL Phenomena in the First Rolling Cycle |
|
|
445 | (1) |
|
12.7.3.5 PEHL Phenomena in the Second Rolling Cycle |
|
|
446 | (1) |
|
12.7.3.6 PEHL Phenomena in the First Five Cycles |
|
|
446 | (1) |
|
12.7.3.7 Effect of Applied Load on the Shakedown or Ratcheting Behavior |
|
|
447 | (1) |
|
12.7.3.8 Effect of Material-Hardening Law on the Shakedown or Ratcheting Behavior |
|
|
447 | (1) |
|
|
448 | (3) |
Chapter 13 EHL of Inhomogeneous Materials |
|
451 | (30) |
|
|
451 | (1) |
|
13.2 EHL with a Single Layer Coating |
|
|
452 | (9) |
|
|
452 | (1) |
|
13.2.2 Model for Point Contact EHL with Single-Layered Coating |
|
|
453 | (1) |
|
13.2.3 Model Verification |
|
|
454 | (1) |
|
13.2.4 Influences of Coating Properties on Point Contact EHL |
|
|
455 | (2) |
|
13.2.5 Influences of Speed, Load, and Lubricant Properties |
|
|
457 | (2) |
|
13.2.6 Curve-Fitting Formulae for Stiff Coating EHL |
|
|
459 | (2) |
|
13.3 EHL with a Multilayered Coating |
|
|
461 | (10) |
|
|
461 | (1) |
|
13.3.2 Theory and Model Description |
|
|
462 | (3) |
|
13.3.2.1 Equations for Lubrication |
|
|
462 | (1) |
|
13.3.2.2 Equations for Surface Displacements and Subsurface Stresses |
|
|
462 | (2) |
|
13.3.2.3 Numerical Solution Procedure |
|
|
464 | (1) |
|
13.3.3 Typical Sample Results |
|
|
465 | (6) |
|
13.3.3.1 EHL with a Bi-Layered Coating |
|
|
465 | (2) |
|
13.3.3.2 EHL with a Multilayered Substrate |
|
|
467 | (2) |
|
13.3.3.3 EHL with a Functionally Graded Coating |
|
|
469 | (2) |
|
|
471 | (1) |
|
13.4 EHL with Gveneral Inhomogeneities |
|
|
471 | (9) |
|
|
471 | (1) |
|
13.4.2 Theory and Model Description |
|
|
472 | (2) |
|
13.4.2.1 Equations for Point Contact EHL |
|
|
472 | (1) |
|
13.4.2.2 Equations for Surface Displacement Calculation |
|
|
472 | (2) |
|
13.4.2.3 Numerical Procedure |
|
|
474 | (1) |
|
13.4.3 Typical Sample Results and Discussions |
|
|
474 | (5) |
|
13.4.3.1 Selected Cases and Computational Mesh |
|
|
474 | (1) |
|
13.4.3.2 A Single Inhomogeneity |
|
|
475 | (2) |
|
13.4.3.3 Multiple Inhomogeneities |
|
|
477 | (1) |
|
13.4.3.4 Functionally Graded Coatings |
|
|
478 | (1) |
|
13.4.4 Computational Efficiency |
|
|
479 | (1) |
|
|
479 | (1) |
|
|
480 | (1) |
Chapter 14 Application Topics |
|
481 | (48) |
|
|
481 | (1) |
|
|
481 | (11) |
|
|
481 | (2) |
|
14.2.2 Mixed EHL in Spur and Helical Gears |
|
|
483 | (5) |
|
14.2.2.1 Gear Geometry and Kinematics |
|
|
483 | (1) |
|
14.2.2.2 Simplified Load Distribution |
|
|
484 | (1) |
|
14.2.2.3 Three-Dimensional Line Contact Mixed EHL Simulation Model |
|
|
485 | (1) |
|
14.2.2.4 Results for a Sample Gear Set in Mixed EHL |
|
|
486 | (1) |
|
14.2.2.5 Gear Tooth Contact Friction |
|
|
487 | (1) |
|
14.2.2.6 Flash and Bulk Temperatures in Gears |
|
|
488 | (1) |
|
14.2.3 Mixed EHL in Spiral Bevel and Hypoid Gears |
|
|
488 | (4) |
|
|
488 | (1) |
|
14.2.3.2 Gearing Geometry and Kinematics |
|
|
489 | (1) |
|
14.2.3.3 Modified Mixed EHL Model |
|
|
490 | (1) |
|
14.2.3.4 Interfacial Friction and Flash Temperature Calculations |
|
|
490 | (1) |
|
14.2.3.5 Sample Results of Calculation |
|
|
490 | (1) |
|
|
491 | (1) |
|
14.3 Pitting Life Prediction for Gears |
|
|
492 | (6) |
|
14.3.1 Problem Description |
|
|
492 | (2) |
|
14.3.2 Pitting Life Prediction Model |
|
|
494 | (1) |
|
14.3.3 Gear Pitting Life Prediction Procedure |
|
|
495 | (2) |
|
14.3.4 Life Prediction Results and Their Comparisons with Testing Data |
|
|
497 | (1) |
|
14.3.5 Effect of Surface Finish on Predicted Pitting Life |
|
|
497 | (1) |
|
14.4 Fatigue Life in Rolling-Sliding Contacts |
|
|
498 | (6) |
|
14.4.1 Problem Description |
|
|
498 | (1) |
|
14.4.2 Asperity Stress Cycle Counting |
|
|
498 | (1) |
|
14.4.3 Life Prediction Procedure |
|
|
499 | (1) |
|
14.4.4 Influence of Relative Sliding on Peak Pressure |
|
|
500 | (2) |
|
14.4.5 Subsurface Stress Variation Due to Sliding |
|
|
502 | (1) |
|
14.4.6 Influence of Sliding on Fatigue Life |
|
|
502 | (2) |
|
14.5 Simulation of Sliding Wear in Mixed Lubrication |
|
|
504 | (6) |
|
14.5.1 Problem Description |
|
|
504 | (1) |
|
14.5.2 Brief Review of Available Wear Models |
|
|
505 | (1) |
|
14.5.3 Wear Simulation Procedure |
|
|
506 | (1) |
|
14.5.4 A Numerical Example |
|
|
507 | (2) |
|
|
509 | (1) |
|
14.5.6 Wear Coefficient Calibration |
|
|
510 | (1) |
|
14.6 Surface Design through Virtual Texturing |
|
|
510 | (8) |
|
14.6.1 Importance of Surface Texture Design and Optimization |
|
|
510 | (2) |
|
14.6.2 Virtual Texturing and Its Procedure |
|
|
512 | (1) |
|
14.6.3 An Application Example |
|
|
513 | (5) |
|
14.6.3.1 Problem Description |
|
|
513 | (1) |
|
14.6.3.2 Determinations of Dimple/Groove Depth, Size, and Density |
|
|
514 | (1) |
|
14.6.3.3 Texture Distribution Pattern Selection |
|
|
514 | (1) |
|
14.6.3.4 Bottom Shapes of the Dimples and Grooves |
|
|
514 | (1) |
|
14.6.3.5 Basic Results of Comparisons |
|
|
514 | (2) |
|
14.6.3.6 Practical Concerns |
|
|
516 | (2) |
|
|
518 | (1) |
|
14.7 EHL with Emulsion Lubricants |
|
|
518 | (9) |
|
|
518 | (2) |
|
|
520 | (1) |
|
14.7.3 Emulsion Lubricants Tested |
|
|
521 | (1) |
|
14.7.4 Oil Pool Formation and Disappearance |
|
|
522 | (1) |
|
14.7.5 Results of Measured Film Thickness |
|
|
523 | (2) |
|
14.7.6 Friction Measurements |
|
|
525 | (1) |
|
|
526 | (1) |
|
|
527 | (2) |
Chapter 15 Multifield Interfacial Issues and Generalized Contact Modeling |
|
529 | (32) |
|
|
529 | (1) |
|
|
529 | (1) |
|
15.1.2 Brief Review of Related Multifield Studies |
|
|
530 | (1) |
|
15.2 Coupled Mechanical-Electrical-Magnetic-Chemical-Thermal (MEMCT) Theory for Material Systems |
|
|
530 | (9) |
|
15.2.1 Fundamental Theories and the MEMCT Framework |
|
|
531 | (6) |
|
15.2.1.1 Multifield Coupling and Fundamental Theories |
|
|
531 | (3) |
|
15.2.1.2 Initial and Boundary Conditions |
|
|
534 | (1) |
|
15.2.1.3 Generalized MEMCT Constitutive Equations |
|
|
534 | (1) |
|
15.2.1.4 Evolution Equations |
|
|
535 | (2) |
|
15.2.2 Generalized MEMCT Theory |
|
|
537 | (2) |
|
15.2.2.1 A Set of Generalized Solutions |
|
|
537 | (1) |
|
|
538 | (1) |
|
15.3 Generalized Contact Model |
|
|
539 | (5) |
|
15.3.1 Contact Model Considerations |
|
|
539 | (1) |
|
15.3.2 Linearized Constitutive Equations and Generalized Boundary Conditions |
|
|
540 | (1) |
|
15.3.3 Generalized Contact and Interfacial Conditions |
|
|
541 | (3) |
|
15.3.3.1 Generalized Gap, Load, and Surface Flux |
|
|
541 | (1) |
|
15.3.3.2 Generalized Contact and Interfacial Conditions for Single-Field Cases |
|
|
541 | (2) |
|
15.3.3.3 Generalized Contact and Interfacial Conditions in Coupled Fields |
|
|
543 | (1) |
|
15.3.3.4 Contact Conditions |
|
|
543 | (1) |
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15.3.3.5 Interfacial Conditions |
|
|
543 | (1) |
|
15.3.3.6 Other Boundary Conditions |
|
|
544 | (1) |
|
15.4 Examples of Contact Subjected to Coupled Fields |
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|
544 | (17) |
|
15.4.1 Sliding Contact Heat Conduction in Homogeneous Materials |
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|
544 | (5) |
|
15.4.1.1 Problem Description |
|
|
544 | (3) |
|
|
547 | (1) |
|
15.4.1.3 Different Modeling Considerations |
|
|
547 | (1) |
|
15.4.1.4 Stress and Temperature Affected by Sliding Velocity |
|
|
548 | (1) |
|
15.4.2 Contact Heat Conduction with Surface Heat Convection |
|
|
549 | (1) |
|
15.4.3 Contact Heat Conduction in an Inhomogeneous Half-Space |
|
|
550 | (4) |
|
15.4.3.1 Problem Description |
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|
550 | (1) |
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15.4.3.2 Analytical Core Solution |
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|
551 | (1) |
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15.4.3.3 Contact and Interfacial Conditions |
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|
551 | (1) |
|
15.4.3.4 Numerical Scheme |
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|
552 | (1) |
|
15.4.3.5 Disturbed Temperature and Heat Flux due to Inhomogeneity |
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|
552 | (1) |
|
15.4.3.6 Effect of Inhomogeneity Size and Location on Disturbed Temperature |
|
|
553 | (1) |
|
15.4.3.7 Effect of Inhomogeneity Distance |
|
|
553 | (1) |
|
15.4.4 Frictional Contact Between Two Multiferroic Materials |
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|
554 | (5) |
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15.4.4.1 Problem Description |
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|
554 | (2) |
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15.4.4.2 Solution Procedure |
|
|
556 | (1) |
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15.4.4.3 Indentation of a Smooth MEE Surface |
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|
557 | (1) |
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15.4.4.4 Indentation of a Rough MEE Surface |
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|
558 | (1) |
|
15.4.4.5 Parameter Sensitivity |
|
|
558 | (1) |
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|
559 | (2) |
Appendix A: Basic Expressions in Linear Elasticity |
|
561 | (2) |
Appendix B: Fourier Series, Fourier Transform, Convolution, and Correlation |
|
563 | (6) |
Appendix C: Solutions of the FRFs for Multilayered Materials Under Normal and Shear Loadings |
|
569 | (6) |
Appendix D: Reference Source Code in FORTRAN for Discrete Convolution and Fast Fourier Transform (DC-FFT) |
|
575 | (4) |
Appendix E: Basic Equations and Their Discretization Schemes for Numerical Solution of Mixed EHL |
|
579 | (8) |
Appendix F: Potential Functions, Derivatives, and Equations Used in Chapter 11 |
|
587 | (6) |
Appendix G: Stresses and Surface Displacement Caused by a Cuboidal Inclusion with Uniformly Distributed Eigenstrain |
|
593 | (4) |
Appendix H: Material Property Parameters and Coefficients for the MEMCT Theory |
|
597 | (6) |
Appendix I: Frequency Response Functions for Surface-Source Induced Temperature and Thermal Elasticity |
|
603 | (4) |
References |
|
607 | |
Index |
|
62 | |