Contact ratio of rough surfaces with multiple asperities in mixed lubrication at high pressures

Relative optical intensity interference was used to measure the lubrication film thickness when four kinds of polyalphaolefin (PAO) were used as lubricants confined between a smooth sapphire disc surface and a rough steel ball surface. Maximum Hertz contact pressure up to 3 GPa was applied in the central part of the contact region in mixed lubrication. It was found that the contact ratio (the ratio of real contact region to the whole nominal contact region) is related to the film thickness, the applied pressure, the surface roughness and the rolling speed, and so on. Contact ratio evidently reduces as lubrication film thickness or rolling speed increases. Quantitative relationship between the contact ratio and the influence factors was summarized based on the nonlinear fitting of experimental measurements. A formula was put forward to calculate the contact ratio at high pressure conditions according to the current experimental results.