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Tribological study of piston–cylinder interface of radial piston pump in high-pressure common rail system considering surface topography effect

Based on the theory of thermal fluid dynamic lubrication, the Reynolds equation and energy equation of the average flow of a piston–cylinder interface of a radial piston pump in a high-pressure common rail system are established, considering the surface topography effect. The tribological properties of the piston–cylinder interface are calculated by solving the Reynolds equation and energy equation. A surface wear model is established and the wear distribution and trend of the piston–cylinder interface are studied. The wear characteristics of the piston–cylinder interface are verified through experiment, and the wear lubrication of the piston–cylinder interface is discussed. The surface topography effect has a considerable influence on the characteristics of the piston–cylinder interface film. Different surface morphologies change the film characteristics of the piston–cylinder interface, yielding different wear behaviors on the mating surface. The wear of the piston–cylinder interface first decreases along the film outlet to the inlet and then rises. The cylinder surface mainly exhibits abrasive, cavitation, and micro-convex scratch wear, whereas the piston surface mainly shows cavitation wear. The results obtained in this study are of considerable significance as they reveal the tribological properties of the piston–cylinder interface under the surface topography effect.