Analysis of the frequency variation trend in rolling bearings with outer ring defects under lubrication starved due to load changes

Purpose This study aims to investigate vibration frequency variations in rolling bearings with outer ring defects under lubrication starvation. Overcoming traditional models’ neglect of lubrication effects, a multi-body dynamics model incorporating mixed lubrication and Hertzian contact theory is developed. It analyzes impacts of starvation parameter χ and radial load on contact forces, cage speed and fault frequency via simulations and experiments. It reveals that starvation increases friction, accelerates cage rotation and elevates fault frequency. Radial load suppresses frequency deviation under starvation. This study provides the theoretical basis for dynamic monitoring of starved bearings in rotating machinery, enhancing fault diagnosis accuracy. Design/methodology/approach This study models frequency variations in rolling bearings with outer ring defects under lubrication starvation. A multi-body dynamics model with mixed lubrication integrates Hertzian contact, rough asperity models, oil film formulas and friction corrections. It analyzes the effects of starvation parameter χ and radial load on contact forces, cage speed and fault frequency. Numerical and experimental validation confirms accuracy. Starvation increases friction, accelerating cage speed, reducing slippage and elevating fault frequency. Radial load suppresses frequency deviation. This study offers a theoretical basis for dynamic monitoring of starved bearings, vital for rotating machinery fault diagnosis. Findings This study reveals that lubrication starvation significantly increases friction in rolling bearings with outer ring defects, accelerating cage rotational speed by 3.41%–2.17% (χ = 0−0.3) and reducing slippage. Higher radial loads further suppress slippage, decreasing fault frequency deviation from 2.44% (100 N) to 1.09% (800 N) at χ = 0.3. The outer ring fault frequency is dynamically modulated by cage speed, with experimental validation confirming simulation predictions. These findings establish a theoretical basis for dynamic frequency correction in fault diagnosis of starved bearings, addressing limitations of conventional fixed-frequency monitoring and enhancing reliability in rotating machinery maintenance. Originality/value This study innovatively models starved lubrication effects on bearing dynamics using mixed lubrication-Hertzian contact theory, revealing that starvation accelerates cage speed and radial load suppresses slippage. Validated via simulations/experiments, it provides dynamic frequency correction for fault diagnosis, overcoming fixed-frequency monitoring limits. Critical for optimizing maintenance in high-load machinery, this work advances tribology-mechanics integration, offering actionable insights for reliability under harsh conditions.