Injection lubrication for high-speed helical gears using the overset mesh method and experimental verification

Zhou, Changjiang; Jiang, Xinghe; Su, Jie; Liu, Yi; Hou, Shifeng

doi:10.1016/j.triboint.2022.107642

Cited by 18 publications

(4 citation statements)

References 36 publications

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“…Use image processing technology to identify the oil volume fraction on the radial section of gears. 43,44 Figure 10 illustrates this analysis principle. The image processing including the preprocessed, gray-scale transformation, binarized, and background removal is carried out to extract the oil pixels.…”

Section: Analysis and Verificationmentioning

confidence: 99%

Splash lubrication for an orthogonal face gear using numerical investigation integrating image processing

Dai,

Yang,

Zhang

et al. 2024

Proceedings of the Institution of Mechanical Engineers, Part J:

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With practical physical immersion depth as their joint, the relations between the oil distribution characteristics and the associated no-load power losses for splash-lubricated orthogonal face gears are explored and quantified in this paper. Firstly, a theoretical analytical model is proposed to estimate the churning losses of an isolated face gear considering all the preceding parameters, along with a numerical model of a face gear stirring oil developed based on the sliding mesh strategy. Then the accuracy and correctness of the computational fluid dynamics method are verified with experiments in terms of oil flow behavior and no-load losses. Finally, the physical immersion depth is determined by leveraging the image processing technique and substituted into the theoretical model replacing the static depth with an improvement of prediction accuracy. Last but not least, this practical immersion depth acts as a link to facilitate the communication between the oil distributions and the no-load power losses within the gearboxes.

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Section: Analysis and Verificationmentioning

confidence: 99%

Splash lubrication for an orthogonal face gear using numerical investigation integrating image processing

Dai,

Yang,

Zhang

et al. 2024

Proceedings of the Institution of Mechanical Engineers, Part J:

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“…Previous studies have proposed general approaches to enhance gear lubrication efficiency, encompassing optimal design of structural characteristics, operating conditions, and oil viscosity-temperature properties. Structural features mainly involve the impact of tooth surface coating, jet distance, jet angle, nozzle diameter and other factors [1][2][3][4][5] on jet lubrication performance. Operating conditions primarily refer to the influence of factors such as oil injection mode, injection speed, injection pressure, gear speed and gearbox movable wall [6][7][8][9][10][11] on lubrication performance.…”

Section: Introductionmentioning

confidence: 99%

Effect of bionic texture on the lubrication efficiency and mechanical efficiency loss for rotating gears

Zhang,

Li,

Zou

et al. 2024

Surf. Topogr.: Metrol. Prop.

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In order to enhance lubrication effectiveness and transmission efficiency in gear transmission, it is imperative to minimize mechanical efficiency losses and frictional wear of the gears during the lubrication process. This paper proposes a bionic design scheme for the tooth surface structure of gears based on the surface texture of bay scallop shells, considering the operational conditions within the gearbox. Firstly, the microstructure of the bay scallop shell surface is analyzed, and a bionic gear mapping model based on the bay scallop shell surface is established. Meanwhile, the oil coverage rate and convective heat transfer coefficient of gear surfaces with different textures was analyzed using finite element analysis. The results showed that the oil coverage rate of gear tooth surfaces with bionic fringes surpassed that of conventional gear lubrication. Thirdly, based on the jet lubrication test calculation, it is proposed that the bionic gear exhibits a smaller torque compared to conventional gears, while the mechanical efficiency of arc groove bionic gear type surpasses that of vertical groove gears. Finally, the optimal structure of the arc groove gear was predicted through orthogonal data analysis, and the validity of the data prediction was verified through experiments and simulations. The optimal combination of texture parameters for the arc groove gear is as follows: a texture depth of 225μm, a texture width of 275μm, a texture interval of 275μm, and a texture length of 1600μm. As a result, lubrication efficiency increased by 41.98%, heat dissipation efficiency increased by 32.21%, and mechanical efficiency increased by 89.39%.

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“…In recent years, there are a lot of research on the lubrication characteristics of spur, 5,6 helical, 7,8 and bevel gears. 9,10 However, there has been relatively less research in the field of lubrication for face gear, 11,12 and even fewer studies on EHL for face gear.…”

Section: Introductionmentioning

confidence: 99%

Modeling and analysis of elastohydrodynamic lubrication of orthogonal face gear with installation errors

Zhou,

Zhu,

Liu

et al. 2024

Proceedings of the Institution of Mechanical Engineers, Part J:

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Installation error is one of the most prominent factors affecting the lubrication of face gear. To analyze the lubrication performance of the face gear with installation errors, the installation error model of the orthogonal face gear transmission system is established. Then, the contact path, equivalent curvature radius, load distribution and entrainment velocity are studied using the face gear loaded tooth contact analysis (LTCA). On this basis, the lubrication governing equations of the face gear are established according to the elastohydrodynamic lubrication (EHL) theory. In addition, the oil film thickness, oil film pressure and coefficient of friction in the process of face gear drives are calculated using the method of progressive mesh densification (PMD). Finally, the effects of axis intersection angle error, axis intersection error and axial displacement error on lubrication characteristics are analyzed. The results reveal that when the axial intersection angle error and axial displacement error are negative and the axial intersection error is positive, the minimum oil film thickness of the face gear tooth surface is less than that without error. When the error values are the same, the minimum oil film thickness and coefficient of friction have larger changes with the axial displacement error than with the axis intersection error, and the contact path has a bigger movement range.

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Injection lubrication for high-speed helical gears using the overset mesh method and experimental verification

Cited by 18 publications

References 36 publications

Splash lubrication for an orthogonal face gear using numerical investigation integrating image processing

Splash lubrication for an orthogonal face gear using numerical investigation integrating image processing

Effect of bionic texture on the lubrication efficiency and mechanical efficiency loss for rotating gears

Modeling and analysis of elastohydrodynamic lubrication of orthogonal face gear with installation errors

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