During liquid drainage from intermediate vessels in various industrial processes such as continuous steel casting, aircraft fuel supply, and chemical separation, free-surface vortices commonly occur. The formation and evolution of these vortices not only entrain surface slag and gas, but also lead to deterioration of downstream product quality and abnormal equipment operation. The vortex evolution process exhibits notable three-dimensional unsteadiness, multi-scale turbulence, and dynamic gas–liquid interfacial changes, accompanied by strong coupling effects between temperature gradients and flow field structures. Traditional macroscopic numerical models show clear limitations in accurately capturing these complex physical mechanisms. To address these challenges, this study developed a mesoscopic numerical model for gas-liquid two-phase vortex flow based on the lattice Boltzmann method. The model systematically reveals the dynamic behavior during vortex evolution and the multi-field coupling mechanism with the temperature field while providing an in-depth analysis of how initial perturbation velocity regulates vortex intensity and stability. The results indicate that vortex evolution begins near the bottom drain outlet, with the tangential velocity distribution conforming to the theoretical Rankine vortex model. The vortex core velocity during the critical penetration stage is significantly higher than that during the initial depression stage. An increase in the initial perturbation velocity not only enhances vortex intensity and induces low-frequency oscillations of the vortex core but also markedly promotes the global convective heat transfer process. With regard to the temperature field, an increase in fluid temperature reduces the viscosity coefficient, thereby weakening viscous dissipation effects, which accelerates vortex development and prolongs drainage time. Meanwhile, the vortex structure—through the induction of Taylor vortices and a spiral pumping effect—drives shear mixing and radial thermal diffusion between fluid regions at different temperatures, leading to dynamic reconstruction and homogenization of the temperature field. The outcomes of this study not only provide a solid theoretical foundation for understanding the generation, evolution, and heat transfer mechanisms of vortices under industrial thermal conditions, but also offer clear engineering guidance for practical production-enabling optimized operational parameters to suppress vortices and enhance drainage efficiency.

Under extreme operating conditions, the internal lubricating flow field of high-speed gear transmission systems exhibits a transient oil–gas multiphase flow, predominantly governed by cavitation-induced phase transitions and turbulent shear. This phenomenon involves complex mechanisms of nonlinear multi-physical coupling and energy dissipation. Traditional lubrication theories and single-phase flow simplified models show significant limitations in capturing microsecond-scale flow features, dynamic interface evolution, and turbulence modulation mechanisms. To address these challenges, this study developed a cross-scale coupled numerical framework based on the Lattice Boltzmann method and large eddy simulation (LBM-LES). By incorporating an adaptive time relaxation algorithm, the framework effectively enhances the computational accuracy and stability for high-speed rotational flow fields, enabling the precise characterization of lubricant splashing, distribution, and its interaction with air. The research systematically reveals the spatiotemporal evolution characteristics of the internal flow field within the gearbox and focuses on analyzing the nonlinear regulatory effect of baffle geometric parameters on the system’s energy transport and dissipation characteristics. Numerical results indicate that the baffle structure significantly influences the spatial distribution of the vorticity field and turbulence intensity by reconstructing the shear layer topology. Low-profile baffles optimize the energy transfer pathway, effectively reducing the flow enthalpy, whereas excessively tall baffles induce strong secondary recirculation flows, exacerbating vortex-induced energy losses. Simultaneously, appropriately increasing the spacing between double baffles helps enhance global lubricant transport efficiency and suppresses unsteady dissipation caused by localized momentum accumulation. Furthermore, the geometrically optimized double-baffle configuration can achieve synergistic improvements in lubrication performance, oil film stability, and system energy efficiency by guiding the main shear flow and mitigating localized high-momentum impacts. This study provides crucial theoretical foundations and design guidelines for developing the next generation of theory-driven, energy-efficient lubrication design strategies for gear transmissions.

Air-shielding radial ultrasonic rolling electrochemical micromachining (AS-RUREMM) is proposed to fabricate high-quality micro-dimple textures on cylindrical SS304 surfaces while suppressing stray corrosion. In AS-RUREMM, an annular air sheath coaxially envelopes the electrolyte jet to confine the wetting footprint, and radial ultrasonic vibration is superimposed on a rolling cathode with micro-protrusions to intensify local mass transport and stabilize the interelectrode environment. A conductivity-centered theoretical framework is established to link air-sheathing-induced gas–liquid distribution, ultrasonic gap modulation, and the resulting current-density localization. Multiphysics simulations in COMSOL 5.3 clarify that moderate air pressure forms a stable confined gas–liquid structure that narrows the effective conductive pathway, whereas excessive air pressure increases intermittency and weakens effective gap conductivity. Experiments on SS304 tubes validate the confinement mechanism: compared with RUREMM, AS-RUREMM produces smaller pit width and depth but a higher depth-to-width ratio, indicating enhanced localization and reduced peripheral over-etching. The simulated cross-sectional profiles agree with measurements, with an overall deviation within 6%. Parameter studies identify an optimal operating window, and the combination of 0.18 MPa air pressure and 12 V pulse voltage provides the highest aspect ratio while maintaining stable machining. SEM/EDX analyses further support the improved process controllability under air shielding through reduced stray corrosion and composition changes consistent with a more regulated electrochemical dissolution environment.