Design/methodology/approach Geometric morphology is integrated into the PEHL model to elucidate the fluid-film properties governed by both macro- and micromorphologies. Findings Results show the model, accounting for combination of elastic and plastic deformations, realistically reveals fluid film distribution affected by the significant pressure highly concentrated within surface micro roughness interaction. The designed macroscopic textured surface mitigates the fluid film rupture phenomenon and prevents accumulated wear degradation from plastic deformation. Originality/value The PEHL model takes into account both elastic and plastic deformations and realistically reveals the fluid film distribution affected by large pressures that are highly concentrated in surface micro-roughness interactions. The macro-textured surfaces are designed to mitigate fluid film rupture phenomena and prevent cumulative wear caused by plastic deformation. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0170/