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<p>To overcome the limitations of conventional approaches in simulating strong thermal‑fluid‑solid interactions, a bidirectional coupled multi‑physics model integrates high‑speed bearing system dynamics, thermal elastohydrodynamic lubrication (TEHL), and oil‑air two‑phase flow analysis is proposed. The proposed framework quantitatively links macroscopic lubricant supply with microscale TEHL contact behavior. Macroscopic lubricant distribution is characterized via three‑dimensional two‑phase flow simulations, enabling a unified description of lubricant transport, film formation, heat generation, and dynamic response under varied operating conditions. Results show that oil‑phase distribution in the bearing cavity exhibits an optimal lubrication window. Film thickening slows when gas pressure exceeds 0.35&#xa0;MPa, and film thickness declines beyond 10 kr/min due to aerodynamic and thermal effects. Quantitatively, each 500 N increase in radial load raises the average film pressure by about 10.68% and reduces the film thickness by about 5.44%. Increasing lubricant viscosity from 22 to 46 mm<sup>2</sup>/s enlarges the minimum film thickness by 24.11% and the maximum pressure by 41.04%. Higher rotational speeds are shown to amplify thermal sensitivity. Validation against an existing model yields a mean absolute percentage error (MAPE) of 3.98% for temperature prediction; however, the relative error (RE) rises to 5.3% above 12 kr/min, confirming that neglecting two-phase flow and dynamic lubrication effects compromises accuracy under high-speed conditions. This study provides a theoretical foundation and quantitative basis for performance optimization and thermal- dynamic co-design for high‑speed spindle systems, aero‑engines, and similar rotating machinery.</p>

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Bidirectional coupling analysis of thermal-dynamic response in high-speed ball bearings

  • 期刊论文

  • 发表日期：

    2026年8月4日

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  • Rui Shi,
  • Yanjun Lü,
  • Ruiying Hu,
  • Tiantian Wang,
  • Ruibo Chen,
  • Xinliang Yang,
  • Yongfang Zhang

摘要

To overcome the limitations of conventional approaches in simulating strong thermal‑fluid‑solid interactions, a bidirectional coupled multi‑physics model integrates high‑speed bearing system dynamics, thermal elastohydrodynamic lubrication (TEHL), and oil‑air two‑phase flow analysis is proposed. The proposed framework quantitatively links macroscopic lubricant supply with microscale TEHL contact behavior. Macroscopic lubricant distribution is characterized via three‑dimensional two‑phase flow simulations, enabling a unified description of lubricant transport, film formation, heat generation, and dynamic response under varied operating conditions. Results show that oil‑phase distribution in the bearing cavity exhibits an optimal lubrication window. Film thickening slows when gas pressure exceeds 0.35 MPa, and film thickness declines beyond 10 kr/min due to aerodynamic and thermal effects. Quantitatively, each 500 N increase in radial load raises the average film pressure by about 10.68% and reduces the film thickness by about 5.44%. Increasing lubricant viscosity from 22 to 46 mm2/s enlarges the minimum film thickness by 24.11% and the maximum pressure by 41.04%. Higher rotational speeds are shown to amplify thermal sensitivity. Validation against an existing model yields a mean absolute percentage error (MAPE) of 3.98% for temperature prediction; however, the relative error (RE) rises to 5.3% above 12 kr/min, confirming that neglecting two-phase flow and dynamic lubrication effects compromises accuracy under high-speed conditions. This study provides a theoretical foundation and quantitative basis for performance optimization and thermal- dynamic co-design for high‑speed spindle systems, aero‑engines, and similar rotating machinery.