Numerical simulations of oil flow inside a gearbox by Smoothed Particle Hydrodynamics (SPH) method

Ji, Zhe; Stanić, Miloš; Hartono, Erwin Adi; Chernoray, Valery

doi:10.1016/j.triboint.2018.05.034

Cited by 60 publications

(26 citation statements)

References 26 publications

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“…Studies and tries performed in order to improve the computational performances are also available [25][26]. Smooth particle hydrodynamics based studies were shown by Groenenboom et al [27], Ji et al [28], Liu et al [29], Rahmatjan and Geni [30], Shi et al [31], Imin and Geni [32], Zhigang et al [33] and Liu et al [34]. A review paper showing advantages and drawbacks of the main available approaches was presented by Concli and Gorla [35].…”

Section: Power Loss Of Gearsmentioning

confidence: 99%

Development of a computational fluid dynamics simulation tool for lubrication studies on cycloidal gear sets

Concli¹,

Maccioni²,

Gorla³

2020

Int. J. CMEM

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In the last decades, the growing mechatronic sector has promoted the development of more and more compact and efficient gearboxes. The margins of improvement are still big even if, sometimes, finding the optimal solutions is a trial and error procedure. For this reason, the development of dedicated tools for the optimization of the geometry and configuration of gearboxes can significantly increase the development effectiveness and help in reducing design costs. Moreover, having a more efficient solution could also reduce thermal problems during operation and increase the system reliability. The so-called 'thermal limit', i.e. the maximum transmittable power without an overheating of the systems, is particularly critical for high power density and compact solutions. Those relies mainly on planetary, harmonic and cycloidal architectures. While many empirical or analytical prediction models can be found in literature for the prediction of the power losses associated with the gear meshing and the bearing, few reliable models are nowadays available for the losses associated with the interaction with the lubricant, i.e. hydraulic losses. Experimental and computational fluid dynamics studies on parallel axis as well as planetary gear sets have been presented in the past. The goal of this research is the extension of the applicability range of those numerical approached to cycloidal kinematics for which no studies at all are available with respect to the hydraulic losses. The main challenge in numerically simulate the lubricant splashing in a cycloidal reduced is related to the topological modification of the computational domain during operation. For this purpose, a specific mesh handling technique, based on a 2.5D mesh, capable to handle the variations of the geometry of the domain was developed in the OpenFOAM® environment. The capability to analytically control the mesh generation at each time step ensures a very high numerical stability and a very high computational efficiency of the solution. Eventually, the approach was systematically applied to a real geometry and the results compared with those obtained for other gear architectures with comparable performances in terms of dimensions and reduction ratios.

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Section: Power Loss Of Gearsmentioning

confidence: 99%

Development of a computational fluid dynamics simulation tool for lubrication studies on cycloidal gear sets

Concli¹,

Maccioni²,

Gorla³

2020

Int. J. CMEM

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show abstract

“…Some research was conducted by the author in order to improve the computational efficiency of the numerical methods [25], [26]. SPH based methods were presented by Groenenboom et al [27], Liu et al [28], Ji et al [29], Shi et al [30], Rahmatjan and Geni [31], Imin and Geni [32], Zhigang et al [33] and Liu et al [34]. A review article showing advantages and limitation of all the available models was presented by Concli and Gorla [35].…”

Section: Power Losses Of Gearsmentioning

confidence: 99%

Lubrication of Gearboxes: CFD Analysis of a Cycloidal Gear Set

Concli

Maccioni

Gorla

2019

Computational and Experimental Methods in Multiphase and Complex Flow X

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In recent years, the increasing demand for more and more compact and efficient solutions has highlighted the need to have appropriate tools in order to optimize the internal design, to avoid thermal problems, ensuring proper lubrication and to increase the reliability of the systems. Typical high power density gearbox designs are based on planetary, harmonic and cycloidal architectures. Although many analytical and numerical models are already available for the prediction of the power losses related to gear meshing (sliding), bearings and seals, literature is lacking in terms of hydraulic power loss models (deep lubrication, churning, windage and squeezing). Some numerical multiphase CFD and experimental studies on parallel axis and planetary gear sets have been already performed by the authors in previous research. The aim of this paper is to extend the applicability of the previously developed numerical techniques to cycloidal architectures, taking into account the typical lubricants used for these type of drives. With respect to the load independent power losses (related to the interaction of the mechanical component and the surrounding lubricant), the cycloidal gear set has been numerically simulated with an especially developed CFD code implemented in the OpenFOAM ® environment. A specific mesh handling technique allows us to manage the topological changes of the domain ensuring the numerical stability of the simulation and the correct calculation of the complex multiphase flows that take place in gearboxes. The results have been compared with those already available for other gear architectures with similar performances (dimensions, reduction ratios and loads).

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“…With focus on the efficiency and thermal behavior, CFD (computational fluid dynamic) seems to be one of the most appropriate tools to study churning losses of mechanical components, including bearings. Among the different CFD-approaches, SPH (smooth particle hydrodynamic), a meshless method, has the advantage of being easily applicable [1] even if the accuracy of the results was shown to be insufficient for comparable computational effort [2]. On the other side, mesh-based methods such as FV (finite volume) allow very high accuracy but in most cases the computational effort required is not compatible with the industrial practice [3].…”

Section: Introductionmentioning

confidence: 99%

Innovative Meshing Strategies for Bearing Lubrication Simulations

2020

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Efficiency improvement is the new challenge in all fields of design. In this scenario the reduction of power losses is becoming more and more a main concern also in the design of power transmissions. Appropriate models to predict power losses are therefore required from the earliest stages of the design phase. The aim of this project is to carry out lubrication simulations of several variants of a cylindrical roller bearing to understand the lubricant distribution and the related churning power losses. Several strategies to reduce the computational effort were used. Among them the sectorial symmetry and three innovative meshing strategies (purely analytical with and without interfaces and analytical/subtractive) that were implemented in the OpenFOAM ® environment. The results of the different approaches were compared among them and reasonable savings in terms of computational effort were shown.

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Numerical simulations of oil flow inside a gearbox by Smoothed Particle Hydrodynamics (SPH) method

Cited by 60 publications

References 26 publications

Development of a computational fluid dynamics simulation tool for lubrication studies on cycloidal gear sets

Development of a computational fluid dynamics simulation tool for lubrication studies on cycloidal gear sets

Lubrication of Gearboxes: CFD Analysis of a Cycloidal Gear Set

Innovative Meshing Strategies for Bearing Lubrication Simulations

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