Blisk, as a critical component of aero−engines, is prone to fatigue cracks that can severely impair its dynamic performance and operational safety. This paper develops a finite element model of a blisk with breathing cracks to investigate the effects of crack distribution (adjacent blades vs. separated blades) and blade twist angle on natural frequencies, frequency−veering and mode localization, and response localization under varying operating conditions. Resonance vibration tests are conducted on blisk and cracked blisk specimens using the frequency dwell method to obtain natural frequencies and vibration responses, thereby experimentally validating the numerical model. The results indicate that cracks reduce the global stiffness, leading to a decrease in natural frequencies and modal localization phenomena. Furthermore, in the frequency−domain responses, nonlinear components such as sub−harmonics, ultra−sub−harmonics, and super−harmonics are observed in addition to the harmonics of the excitation frequency. Moreover, the cracked blisk with a 45° blade twist angle exhibits typical nonlinear vibration behaviors and the most pronounced response localization. This study provides a basis for crack monitoring and resonance fatigue warning.

The floating oil seal (FOS) is a critical component in coal mining machinery, where frictional wear and high stress on the O-ring can lead to oil leakage and eventual FOS failure, significantly impairing equipment performance. To address this issue, this study proposes a novel ceramic-coated floating oil seal (NCCFOS) composite structure that enhances wear resistance without modifying the existing sealing cavity configuration. A two-dimensional axisymmetric finite element model of the NCCFOS was developed based on the Mooney–Rivlin constitutive model, considering the O-ring assembly process for improved accuracy. The model was analyzed under oil pressure loading, with parametric studies examining the influence of oil pressure, assembly clearance, and material hardness on O-ring stress, contact pressure, and frictional stress distribution in the floating seal ring. The results demonstrate that accounting for the assembly process yielded more realistic stress predictions compared to conventional modeling approaches. The NCCFOS design effectively mitigated stress concentrations, reduced O-ring wear, and extended fatigue life, offering a practical solution for enhancing the reliability of coal mining machinery seals.