This article focuses on the problem of sealing failure in high-speed micro bearings. Based on a thermal-stress coupled finite element model, the distribution of equivalent stress and contact pressure of the sealing ring and the influence of various factors on the sealing performance are analyzed. Based on this, the Latin Hypercube sampling method, Kriging surrogate model and genetic algorithm are used to find the optimal combination of sealing performance. Finally, the accuracy of the model and method is verified through orthogonal experiments. Research has found that the maximum equivalent stress of the seal ring is 0.59234 MPa, and it increases first and then decreases with the increase in lip inclination angle, friction coefficient and radial interference amount, increases with the increase in lubricant temperature, and decreases with the increase in bearing rotation speed. The maximum contact pressure is 0.20433 MPa, and it decreases with the increase in the lip inclination angle, increases first and then decreases with the increase in the friction coefficient, and decreases first and then increases with the increase in the lubricant temperature, bearing rotation speed and radial interference amount. The most significant factor affecting the equivalent stress of the seal ring is the lubricant temperature, and the most significant factor affecting the contact stress is the interference fit amount. When the seal lip inclination angle is 43.99°, the friction coefficient is 0.01 mm, the lubricant temperature is 111.5 °C, the bearing rotation speed is 28,853 rpm and the radial interference amount is 0.04 mm, the sealing performance of the sealing ring is optimal.

This paper focuses on the sealing failure problem of double-lip seal rings for high-speed ball bearings used in unmanned aerial vehicles. By using ANSYS 2023R1 software, a thermal–stress–wear coupled finite element model was established. Taking the contact pressure and volume loss due to wear as indicators to evaluate sealing performance, this study analyzed the influence of lip seal structural parameters on sealing performance, performed response surface optimization of the seal structure parameters and conducted a comparative test on lip seals before and after optimization. The research results show that the contact pressure at the main lip of the lip seal was the greatest, which was 0.79 MPa, and the volume loss due to wear lip seal was 7.94 × 10⁻⁷ mm³. Optimal sealing performance is achieved when the seal lip inclination angle is 41.68°, the middle width of the lip seal is 0.153 mm, the main lip height is 0.179 mm, the spring center distance is 0.37 mm and the radial interference is 0.0034 mm. After optimization, the grease leakage rate of the sealing ring decreased by 48% compared to before optimization.