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<p>Wind turbine main bearings operating under extreme loads and boundary lubrication conditions face significant wear challenges, necessitating advanced surface engineering solutions. A self-lubricating coating has been considered as a potential strategy to achieve steady operation and extend the lifetime of the wind turbine main bearings. This study systematically investigates the effect of a poly-ether-ether-ketone (PEEK) self-lubricating coating on the friction and wear performance of spherical roller main bearings in wind turbines. Tribological tests were conducted using a ball-on-disc tribometer to characterize the friction and wear behavior of GCr15SiMn steel substrates with and without PEEK coatings under dry sliding conditions. Experimental results reveal that the PEEK coating reduces the friction coefficient by 45% (from 0.55 to 0.30) and wear rate by three orders of magnitude (from 6.87 × 10⁻⁶ to 1.36 × 10⁻⁸ mm³/ (N·mm)), attributed to its self-lubricating properties. A validated three-dimensional finite element model was then developed to investigate contact mechanics and wear distribution in coated bearings under realistic wind turbine loads. Simulation results demonstrate that the PEEK coating mitigates stress concentration at the outer ring-roller interface, reducing maximum contact pressure by 78% (from 1064.4&#xa0;MPa to 230.42&#xa0;MPa) and altering wear patterns. This integrated experimental-numerical framework provides critical insights into the wear mitigation mechanisms of PEEK coatings, innovatively combining tribological experiments with validated finite element modeling to address extreme load challenges in wind turbines, offering a theoretical foundation for optimizing bearing designs in renewable energy systems.</p>

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Numerical analysis of wear characteristics of wind turbine main bearings with self-lubricating coating

  • 期刊论文

  • 发表日期：

    2026年5月8日

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  • Shenghui Ma,
  • Xiaochun Cai,
  • Minggui Liang,
  • Haoyang Huang,
  • Mingliang Ji,
  • Zhengjia Ji

摘要

Wind turbine main bearings operating under extreme loads and boundary lubrication conditions face significant wear challenges, necessitating advanced surface engineering solutions. A self-lubricating coating has been considered as a potential strategy to achieve steady operation and extend the lifetime of the wind turbine main bearings. This study systematically investigates the effect of a poly-ether-ether-ketone (PEEK) self-lubricating coating on the friction and wear performance of spherical roller main bearings in wind turbines. Tribological tests were conducted using a ball-on-disc tribometer to characterize the friction and wear behavior of GCr15SiMn steel substrates with and without PEEK coatings under dry sliding conditions. Experimental results reveal that the PEEK coating reduces the friction coefficient by 45% (from 0.55 to 0.30) and wear rate by three orders of magnitude (from 6.87 × 10⁻⁶ to 1.36 × 10⁻⁸ mm³/ (N·mm)), attributed to its self-lubricating properties. A validated three-dimensional finite element model was then developed to investigate contact mechanics and wear distribution in coated bearings under realistic wind turbine loads. Simulation results demonstrate that the PEEK coating mitigates stress concentration at the outer ring-roller interface, reducing maximum contact pressure by 78% (from 1064.4 MPa to 230.42 MPa) and altering wear patterns. This integrated experimental-numerical framework provides critical insights into the wear mitigation mechanisms of PEEK coatings, innovatively combining tribological experiments with validated finite element modeling to address extreme load challenges in wind turbines, offering a theoretical foundation for optimizing bearing designs in renewable energy systems.