Optimized Design and Lubrication Friction Performance of Elliptical Micro-textures in Gear Surfaces

• • Optimal elliptical texture parameters (h=20 μm, ra=150 μm, γ=0.7, θ=0°) reduced maximum and minimum damage area ratios by 81.11% and 76.97%, respectively, in gear tests, shifting wear from severe adhesive to minor scratching. This directly extends gear service life in marine and heavy machinery, reducing unplanned downtime and maintenance costs. • • Area ratio and inclination angle are the most significant factors affecting lubrication performance, with optimal values around 25%-30% and 45°, respectively. This provides a clear design window for engineers, avoiding trial-and-error and accelerating industrial adoption of surface texturing. • • Under rolling-sliding line contact, elliptical textures with longer major axes (at constant ellipticity) more effectively reduce friction, as confirmed by CFD and orthogonal wear tests. This geometric insight enables tailored texture designs for specific gear geometries, enhancing tribological efficiency. • • Improper parameter combinations can exacerbate wear, highlighting the necessity of systematic optimization. The study's orthogonal experimental design identified robust parameter sets, mitigating the risk of detrimental textures in practical applications.