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This paper aims to provide a reliable and efficient numerical piston–cylinder design method and assess the effect of clearance on the piston-cylinder lubrication.

Numerical analyses of lubrication characteristics were performed for the piston–cylinder interface. The axial piston was numerically modeled, and the film pressure was calculated using the unsteady two-dimensional Reynolds equation. The behavior of the piston was analyzed by calculating the eccentricity satisfying the force and moment balance.

The secondary motion of the piston included numerically simulated several cycles until the piston behavior converged, and contact with the inner wall of the cylinder and friction region was estimated. Results showed that the piston–cylinder clearance affected the contact force, length of the contact region and leakage flow rate.

This result improves the understanding of the piston–cylinder lubrication and suggests considerations in terms of lubrication in clearance design.

This paper aims to propose a new scuffing model caused by the depletion of additives in boundary lubrication condition.

The differential equation governing the distribution of additive content in the fluid film was used. This formula was derived from the principle of mass conservation of additives considering the consumption due to surface adsorption of wear particles. The occurrence of scuffing was determined by comparing the wear rate of the oxide layer with the oxidation rate.

If the additive becomes depleted while sliding, the scuffing failure occurs even at a low-temperature condition below the critical temperature. The critical sliding distance at which scuffing failure occurred was suggested. The experimental data of the existing literature and the theoretical prediction using the proposed model are shown to be in good agreement.

It is expected to be used in the design of oil supply grooves for sliding bearings operating under extreme conditions or in selecting the minimum initial additive concentration required to avoid scuffing failure under given contact conditions.