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This paper aims to study the influence of different seal structure parameters and working conditions on the air-oil two-phase flow characteristics and leakage characteristics of the seal cavity in the bearing cavity of the aero-engine spindle bearing tester.

In this paper, the VOF method and RNG k-ε turbulence model are used to explore the flow characteristics and leakage characteristics of the labyrinth seal cavity of an aero-engine spindle bearing tester under the condition of air-oil two-phase flow.

The distribution of the lubricating oil is related to the sealing clearance and the air-oil ratio. The amount of oil leakage increases with increasing of sealing chamber clearance, air-oil ratio and inlet velocity and decreases with increasing curvature and speed. The amount of air leakage increases with sealing clearance and inlet velocity.

In comparison to the pure air-phase flow field, the air-oil two-phase flow field can more accurately simulate the lubricating oil flow in the sealing chamber.

With respect to severe working conditions such as heavy load and impact, this paper aims to investigate the friction reduction and anti-wear performance of kaolin and molybdenum dialkyl dithiophosphate (MoDDP) composite lubricant additives to improve the lubrication effect of a single additive.

A four-ball friction test was carried out to determine the optimal concentration of kaolin and organic molybdenum additives and the tribological properties of the kaolin/MoDDP composite lubricant additives. A ring block test of composite lubricant additives was designed to investigate its lubrication performance under the severe working conditions of low speed, heavy load and impact.

The results showed that the optimal addition mass fractions of kaolin and MoDDP were 4.0 and 1.5 Wt.%, respectively, when kaolin and MoDDP were used as single lubricant additives. Compared with the single additive, the 4.0 Wt.% kaolin/1.5 Wt.% MoDDP composite lubricant additive showed excellent friction reduction and anti-wear effects under heavy load and impact conditions. Physicochemical analysis of the wear surface revealed that the lamellar kaolin additive and MoDDP had excellent synergistic effects, and the friction process promoted the generation of lubricant films containing a chemically reactive layer of MoS₂, MoO₂, FeS₂ and Fe₂O₃ and a physically adsorbent layer containing SiO₂ and Al₂O₃, which play important roles in anti-wear and friction reduction.

The excellent friction reduction and anti-wear effects of lamellar silicate minerals and the excellent antioxidant properties and good synergistic effects of molybdenum were comprehensively used to develop the composite additives with great lubricating properties.