Verification and Analysis of Wear and NVH in High-Speed Deep Groove Ball Bearings for New Energy Vehicles
Background
As new energy vehicles (NEVs) continue to demand higher performance and reliability from electric drive systems, high-speed bearings are required to achieve higher rotational speeds, improved efficiency, lower noise, vibration and harshness (NVH), extended service life, and enhanced operational reliability. Throughout their service life, these bearings must maintain low friction, minimal wear, and stable acoustic performance.
Preventing abnormal bearing wear and NVH-related issues has become one of the most critical factors influencing electric drive system performance and market competitiveness.
Previous studies have investigated various aspects of bearing wear and vibration behavior. Ye Chao et al. analyzed the effects of bearing inner-ring center offset and uniform ball wear on vibration performance, concluding that uniform ball wear generates significant ball-pass frequencies and cage modulation frequencies. Li Hongliang et al. conducted failure analysis on surface wear of cryogenic high-speed bearing balls used in rocket engines, finding that insufficient surface hardness can lead to abnormal wear or spalling, while fixed-axis rotation of balls under ultra-high-speed conditions accelerates the formation of wear bands. Chen Fei et al. studied the synergistic effects of Si₃N₄ whiskers and graphene on improving the hardness of ceramic ball materials, demonstrating that oxide additives significantly reduce friction coefficients and enhance wear resistance. Zhang Yu et al. investigated the influence of internal design parameters on wear and temperature rise in full-ceramic ball bearings under extreme conditions such as high-speed operation and starved lubrication, using raceway wear depth and radial stiffness as objective functions. YU et al. applied the Archard wear model to evaluate the effects of axial load, rotational speed, and structural parameters on bearing wear life. MORALES-ESPEJEL et al. assessed bearing service life by considering both surface fatigue and subsurface fatigue, introducing key parameters such as lubrication conditions, contamination levels, surface geometry, and frictional stresses to separately evaluate these failure mechanisms.
Although extensive research has been conducted on general bearing applications, studies focusing on wear and NVH issues in high-speed bearings for NEV electric drive systems under complex and severe operating conditions—including frequent start-stop cycles, wide temperature fluctuations, ultra-high speeds, unstable lubrication, poor lubricant cleanliness, and misalignment—remain limited.
Therefore, this article analyzes representative case studies to identify and verify the key factors influencing bearing wear and NVH performance. The findings aim to provide practical guidance and optimization directions for improving the reliability and acoustic performance of high-speed bearings used in new energy vehicles.
Abstract
Based on actual operating conditions of new energy vehicles, verification tests and analyses were conducted on wear and NVH performance of high-speed deep groove ball bearings under several representative operating scenarios, including:
High-speed and low-speed extreme conditions
Low-speed start-stop and continuous running conditions
High-speed start-stop and continuous running conditions
The results indicate that lubrication-related factors—including lubricant supply volume, lubricant arrival time, and oil film thickness—as well as lubricant cleanliness, rotational speed, and high/low temperature conditions are the primary causes of abnormal bearing wear and subsequent noise generation.
Additional analyses were performed considering geometric tolerances, cleanliness control, and bearing dynamic behavior. Through comprehensive experimental validation and root-cause analysis, it was concluded that:
Proper control of lubricant cleanliness significantly reduces wear-related failures.
Increasing ceramic ball diameter enhances bearing robustness and operational stability.
These measures can fundamentally mitigate bearing wear and abnormal noise issues in electric drive systems.
The findings provide valuable technical guidance for improving the wear resistance, NVH performance, and overall reliability of high-speed deep groove ball bearings used in new energy vehicles.
Conclusions
Lubrication conditions, material selection, operating profiles, temperature variations, and geometric tolerances all have significant impacts on the wear behavior and NVH performance of high-speed deep groove ball bearings used in new energy vehicles.
By comprehensively addressing these factors, particularly through:
Fine-grained lubricant cleanliness control based on bearing size classifications
Increased ceramic ball diameter
the study successfully mitigated bearing wear and NVH issues.
Furthermore, lubrication arrival time before operation and optimized lubrication strategies should also be carefully considered to further enhance the performance and reliability of high-speed bearings in electric drive systems.
In practical applications, high-quality data collection through online monitoring systems should be strengthened. Continuous accumulation of operational data and engineering experience will support the development of friction and wear prediction models for NEV high-speed bearings. By applying intelligent training and predictive analytics, it will become possible to:
Predict fatigue evolution patterns
Assess remaining useful life
Develop targeted validation methodologies
Establish comprehensive evaluation systems
Achieve precise, real-time intelligent diagnostics and maintenance throughout the entire operating lifecycle
Such advancements will provide a solid foundation for the next generation of highly reliable and intelligent electric drive systems.
Reference
Source:
Li Junqing. Verification and Analysis of Wear and NVH of High-Speed Deep Groove Ball Bearings for New Energy Vehicles [J]. Bearing, 2026(5):84–91.
As new energy vehicles (NEVs) continue to demand higher performance and reliability from electric drive systems, high-speed bearings are required to achieve higher rotational speeds, improved efficiency, lower noise, vibration and harshness (NVH), extended service life, and enhanced operational reliability. Throughout their service life, these bearings must maintain low friction, minimal wear, and stable acoustic performance.
Preventing abnormal bearing wear and NVH-related issues has become one of the most critical factors influencing electric drive system performance and market competitiveness.
Previous studies have investigated various aspects of bearing wear and vibration behavior. Ye Chao et al. analyzed the effects of bearing inner-ring center offset and uniform ball wear on vibration performance, concluding that uniform ball wear generates significant ball-pass frequencies and cage modulation frequencies. Li Hongliang et al. conducted failure analysis on surface wear of cryogenic high-speed bearing balls used in rocket engines, finding that insufficient surface hardness can lead to abnormal wear or spalling, while fixed-axis rotation of balls under ultra-high-speed conditions accelerates the formation of wear bands. Chen Fei et al. studied the synergistic effects of Si₃N₄ whiskers and graphene on improving the hardness of ceramic ball materials, demonstrating that oxide additives significantly reduce friction coefficients and enhance wear resistance. Zhang Yu et al. investigated the influence of internal design parameters on wear and temperature rise in full-ceramic ball bearings under extreme conditions such as high-speed operation and starved lubrication, using raceway wear depth and radial stiffness as objective functions. YU et al. applied the Archard wear model to evaluate the effects of axial load, rotational speed, and structural parameters on bearing wear life. MORALES-ESPEJEL et al. assessed bearing service life by considering both surface fatigue and subsurface fatigue, introducing key parameters such as lubrication conditions, contamination levels, surface geometry, and frictional stresses to separately evaluate these failure mechanisms.
Although extensive research has been conducted on general bearing applications, studies focusing on wear and NVH issues in high-speed bearings for NEV electric drive systems under complex and severe operating conditions—including frequent start-stop cycles, wide temperature fluctuations, ultra-high speeds, unstable lubrication, poor lubricant cleanliness, and misalignment—remain limited.
Therefore, this article analyzes representative case studies to identify and verify the key factors influencing bearing wear and NVH performance. The findings aim to provide practical guidance and optimization directions for improving the reliability and acoustic performance of high-speed bearings used in new energy vehicles.
Abstract
Based on actual operating conditions of new energy vehicles, verification tests and analyses were conducted on wear and NVH performance of high-speed deep groove ball bearings under several representative operating scenarios, including:
High-speed and low-speed extreme conditions
Low-speed start-stop and continuous running conditions
High-speed start-stop and continuous running conditions
The results indicate that lubrication-related factors—including lubricant supply volume, lubricant arrival time, and oil film thickness—as well as lubricant cleanliness, rotational speed, and high/low temperature conditions are the primary causes of abnormal bearing wear and subsequent noise generation.
Additional analyses were performed considering geometric tolerances, cleanliness control, and bearing dynamic behavior. Through comprehensive experimental validation and root-cause analysis, it was concluded that:
Proper control of lubricant cleanliness significantly reduces wear-related failures.
Increasing ceramic ball diameter enhances bearing robustness and operational stability.
These measures can fundamentally mitigate bearing wear and abnormal noise issues in electric drive systems.
The findings provide valuable technical guidance for improving the wear resistance, NVH performance, and overall reliability of high-speed deep groove ball bearings used in new energy vehicles.
Conclusions
Lubrication conditions, material selection, operating profiles, temperature variations, and geometric tolerances all have significant impacts on the wear behavior and NVH performance of high-speed deep groove ball bearings used in new energy vehicles.
By comprehensively addressing these factors, particularly through:
Fine-grained lubricant cleanliness control based on bearing size classifications
Increased ceramic ball diameter
the study successfully mitigated bearing wear and NVH issues.
Furthermore, lubrication arrival time before operation and optimized lubrication strategies should also be carefully considered to further enhance the performance and reliability of high-speed bearings in electric drive systems.
In practical applications, high-quality data collection through online monitoring systems should be strengthened. Continuous accumulation of operational data and engineering experience will support the development of friction and wear prediction models for NEV high-speed bearings. By applying intelligent training and predictive analytics, it will become possible to:
Predict fatigue evolution patterns
Assess remaining useful life
Develop targeted validation methodologies
Establish comprehensive evaluation systems
Achieve precise, real-time intelligent diagnostics and maintenance throughout the entire operating lifecycle
Such advancements will provide a solid foundation for the next generation of highly reliable and intelligent electric drive systems.
Reference
Source:
Li Junqing. Verification and Analysis of Wear and NVH of High-Speed Deep Groove Ball Bearings for New Energy Vehicles [J]. Bearing, 2026(5):84–91.
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