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This work presents an architecture for multi-physical numerical calculations of ball bearing contacts based on OpenFOAM. It is built according to the state-of-the-art for fluid-solid interaction and extends towards electro-quasi-static fields. With the presented approach, the electrical properties of concentrated tribological contacts become computable. Measurements of raceway surface damages are embedded into the numerical grid to evaluate the capabilities of the calculation procedure. The calculations carried out on this grid offer new insights into how surface degradation affects the electrical properties of tribological contacts in rolling bearings, which would be impossible with classical calculations.
•The EHL in rolling element bearings can be utilised as a sensor when applying AC (impedance)•Pitting damage in ball bearings causes characteristic peaks in the impedance signal.•In contrast to empirical models, a finite-volume approach can represent regular and irregular surfaces.