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• A tribo-dynamic analysis procedure is developed for the predictions of the aero ball bearing with 3D measured roughness. • The influences of structure parameters and running conditions on the bearing dynamic performance have been discussed. • The roughness effects on lubrication state and friction-temperature of the aero ball bearing are investigated. • The 3D dynamic subsurface stress of the aero ball bearing has been researched. Tribological failures, like wear, scuffing and pitting, etc, often occur in aero ball bearings due to large dry contact area, high friction-flash temperature and stress concentration at the interface between the contacting ball and race. In this paper, a numerical tribo-dynamic analysis procedure is developed for the predictions of dynamic performance, lubrication state, friction-temperature, and subsurface stress of the aero ball bearing with 3D measured roughness. The numerical model is verified by comparing the friction coefficients with the testing results, which show well agreements and proves the presented model is available. The dynamic performance of bearing at different azimuth angle are studied, which indicate the increasing radial load and speed result in more asymmetric distributions of the contact load, stress and slide-roll ratio, the maximum values and the unloaded-region become larger. With the increase of the inner race groove coefficient and the contact angle, the pv value and the radial stiffness decrease clearly. The tribology behaviors of the ball bearing are also investigated, the obtained results indicate that the heavy-load and low-speed lead to large dry contact areas, high friction-temperature, and high local stress peaks, the lubrication state become worse, which may further cause the failures of mass wear, scuffing and micro-pitting. [ABSTRACT FROM AUTHOR]

• A comprehensive stiffness model of intermediate bearing is presented. • A reduced model of dual rotor-bearing-casing coupling system is developed. • The effects of typical parameters on the vibration of the system are discussed. • The mechanism of the comprehensive stiffness and system vibration is revealed. This paper focuses on the vibrational properties of a dual rotor-casing coupled system with nonlinear clearance in the intermediate bearing, considering both the oil film stiffness and Hertzian contact stiffness between rolling elements and raceways. A comprehensive stiffness model for the intermediate bearing has been developed based on elastohydrodynamic lubrication (EHL) and Hertz contact theory. Subsequently, a dynamical model of the dual rotor-bearing-casing system is established using the finite element method, thereby verifying the feasibility of simulating the casing with beam elements. The dimensionality of the system equation is reduced using the fixed-interface component mode synthesis (CMS) method, and the resulting reduced-dimensionality equation is solved using the improved Newmark- β method. The effects of casing support, rotational speed, and radial clearance on the vibration characteristics of the system are investigated. Then, the comprehensive stiffness and coupled vibration characteristics of the system are analyzed to elucidate its intrinsic mechanism. Finally, the contact characteristics within the intermediate bearing under dynamic load are also studied. The results indicate that the support stiffness of the casing has a more significant impact on the second resonance caused by both the inner and outer rotors. The system is prone to experiencing varying compliance (VC) resonance at low rotational speeds. The excessive bearing clearance leads to complex vibrational characteristics of the system, making it challenging to predict its motion. The impact of minor changes in stiffness on system vibration is small when the comprehensive stiffness is large. At this time, the limited effect of oil film stiffness allows it to be disregarded in terms of comprehensive stiffness. Furthermore, the speed significantly influences the contact characteristics within the intermediate bearing under the unbalanced force of the rotor and gravity. [ABSTRACT FROM AUTHOR]