Abstract This study presents a numerical investigation of the hydrodynamic performance of textured surfaces under lubrication, emphasizing the influence of texture geometry and manufacturing defects. Rectangular and semi-elliptical textures are compared using a fully coupled finite element model based on the Navier–Stokes equations, which overcomes limitations of Reynolds-based approaches near texture edges with steep gradients. The analysis evaluates pressure distribution, load capacity, flow patterns, and shear stresses for textures with identical depth-to-length ratios across varying Reynolds numbers. Semi-elliptical textures exhibit superior performance, generating higher lift and more stable flow with reduced separation, though they induce greater drag. The study also examines manufacturing deviations causing inclined sidewalls in rectangular textures, showing that deep cavities benefit, shallow ones lose load capacity, friction increases, but shorter textures remain less sensitive, making them preferable for practical applications. These findings provide insights for designing textured surfaces that balance friction reduction and load support under varying operating conditions.
Aboussafy et al. (Tue,) studied this question.