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Statistical investigation on the failure of misaligned contaminated EHL rolling contacts using response surface methodology

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Abstract

This experimental research work is conducted to determine statistical models of wear evolution and surface roughness components in a misaligned contaminated EHL rolling contact. To achieve this goal, experiments were realized on an original test rig representing the real operating conditions of gears or roller bearings. In fact, the rolling contact tests are carried out using the contact between two steel disks with the presence of misalignment defect and solid contaminants within lubricant oil. In order to investigate the influence of four operating input variables like misalignment angle (α), rotational velocity (V), load (Q), and contaminant concentration (C) on the studied responses (i.e., wear (W) and surface roughness components (Ra, Rt, and Rz)), the Box-Behnken design (BBD) was adopted. Thereafter, the results obtained were analyzed using both response surface methodology (RSM) and analysis of variance (ANOVA). It is found that the rotational velocity (V) is the most significant factor affecting the wear (W) and the surface roughness components (Ra, Rt, and Rz) of a misaligned contaminated EHL rolling contact with 75.51%, 79.2%, 89.07%, and 59.65% of contributions, respectively, whereas load (Q), misalignment angle (α), contaminant concentration (C), and two-level interaction effect (α × C and C × Q) are significant factors but have a lesser effect on the wear variability with 8.23%, 5.57%, 2.42%, 2.68%, and 2.62% contributions, respectively. It is also deduced that the misalignment angle (α) is statistically significant when studying the mean depth roughness (Rz) with 15.67% of contributions. Finally, it is revealed that the obtained higher values of determination coefficient (more than 90%) show clearly the reliable of the implemented quadratic models.

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Funding

The authors would like to thank the Algerian Ministry of Higher Education and Scientific Research (MESRS) for granting financial support for PRFU Research Project—Code: A11N01UN230120190004 (Badji Mokhtar University, Annaba).

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Authors and Affiliations

  1. Mechanics of Materials and Plant Maintenance Research Laboratory (LR3MI), Mechanical Engineering Department, Faculty of Engineering, Badji Mokhtar University of Annaba (UBMA), PO Box 12, 23052, Annaba, Algeria

    Abdelmalek Mostefaoui & Mohamed Rafik Sari

  2. Mechanical Engineering Department, University of 20 Aout 1955, El Hadaiek Road, B. O. 26, 21000, Skikda, Algeria

    Abdelmalek Mostefaoui & Mohamed Kezzar

  3. Materials and Energy Engineering Laboratory (LMGE), Technology Department, Faculty of Technology, 20 Aout 1955 University of Skikda, PO Box 26, 21000, Skikda, Algeria

    Mohamed Kezzar

  4. Department of Mathematics, Faculty of Science, New Valley University, El-Kharga, Al-Wadi Al-Gadid, 72511, Kharga Oasis, Egypt

    Mohamed R. Eid

  5. Department of Mathematics, Faculty of Science, Northern Border University, Arar, 1321, Saudi Arabia

    Mohamed R. Eid

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  1. Abdelmalek Mostefaoui
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  2. Mohamed Rafik Sari
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  3. Mohamed Kezzar
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  4. Mohamed R. Eid
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Correspondence to Mohamed Rafik Sari.

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Mostefaoui, A., Sari, M.R., Kezzar, M. et al. Statistical investigation on the failure of misaligned contaminated EHL rolling contacts using response surface methodology. Int J Adv Manuf Technol 127, 1225–1242 (2023). https://doi.org/10.1007/s00170-023-11438-6

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  • DOI: https://doi.org/10.1007/s00170-023-11438-6

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