Computational Modeling and Prediction of Lubricated Wear in Cam–Follower Mechanisms Using Dynamic Analysis and Elastohydrodynamic Film Thickness Evaluation

Abstract

This study presents a comprehensive computational framework for predicting lubricated wear in cam–follower mechanisms commonly used in internal combustion engines. The system's tribological behavior was modeled under dynamic loading conditions using a flat-faced follower and Polydyne cam profile. A combined approach involving dynamic force analysis, Hertzian contact pressure, and Archard’s wear model was implemented in MATLAB to simulate material degradation. Additionally, the Dowson–Hamrock formulation was used to estimate minimum elastohydrodynamic (EHL) film thickness, incorporating lubricant properties, speed, and contact load. The model was extended to include tribocorrosion effects by introducing a corrosion index into the wear equation. Experimental validation using Scanning Electron Microscopy (SEM) and Atomic Force Microscopy (AFM) confirmed surface roughness evolution and wear mechanisms. Results revealed strong agreement between predicted and observed wear volumes, with DLC-coated steel outperforming other materials in wear resistance. Film thickness ratio (λ) was found to be a critical factor in minimizing surface degradation. This integrated modeling approach can aid in optimizing material selection and lubrication strategies for high-performance valve train systems.