An Adhesive Wear Model for Gears in Mixed Elastohydrodynamic Lubrication

In this study, an adhesive wear model for a gear drive in mixed elastohydrodynamic lubrication (EHL) is proposed. The mixed-EHL model combines the average Reynolds equation with the ZMC rough-surface contact model to determine the asperity contact pressure. By incorporating the fractional film defect into the Archard wear equation, a wear rate model under mixed EHL is developed and verified against published experimental data. This wear-rate model is subsequently coupled with a transient line-contact mixed-EHL model for gears to establish a tooth-surface wear prediction model that iteratively updates the tooth geometry and contact pressure. The evolution of tooth-surface wear under mixed EHL is investigated, and the resulting wear characteristics are compared with those under dry-contact conditions. The influence of tooth-surface roughness is also systematically evaluated. The results indicate that tooth-surface wear is substantially reduced under mixed EHL and that the maximum wear occurs between the lowest point of single-tooth contact and the pitch point. Increasing surface roughness intensifies wear and shifts the maximum-wear location toward the tooth root. These findings demonstrate that appropriate lubricant selection and effective control of tooth-surface roughness are important for improving the wear resistance of gear drives.