Optimization of mesh density for numerical simulations of hydrodynamic lubrication considering textured surfaces

In this work, a parametric study of a lubricated textured contact is carried out using a numerical model. The model solves the Reynolds equation coupled with a mass-conserving cavitation algorithm, and addresses the hydrodynamic lubrication of a mechanical seal with textured surfaces. Three shapes of texture (square, spherical cap, and triangle) are used, and the effect of the aspect ratio is also discussed for the case involving a triangular dimple. In order to estimate quantitatively the discretization error, the grid convergence index method is applied, considering several operating parameters (leakage, cavitation, load-carrying capacity) and using three grid levels: coarse (100 × 100), medium (200 × 200), and fine (400 × 400). As could be expected, grid convergence index analysis showed that there was a reduction in the discretization error when the grid system was refined. However, the study also showed that medium grid (200 × 200) solution has a grid convergence index of <6%. Comparison between fine...