The paper focuses on the numerical determination of Patir and Cheng’s flow factors for general roughness patterns. Improved procedures for the generation of surface roughness and flow simulation are presented. It is shown that application of these techniques resolves differences to analytical solutions of Elrod and Tripp and reduces the scatter in the results to a reasonable degree. Flow factor charts are given for the ‘standard’ Gaussian/Peklenik roughness and for sintered surfaces with high skewness.

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