Oil distribution and churning losses of gearboxes: Experimental and numerical analysis

Mastrone, Marco Nicola; Hartono, Erwin Adi; Chernoray, Valery; Concli, Franco

doi:10.1016/j.triboint.2020.106496

Cited by 53 publications

(26 citation statements)

References 28 publications

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“…From the numerical perspective, several numerical schemes have been proposed in the literature in the past decades for the numerical simulation of two phase flows in which the interface computation is a critical component [8,9,21,22]. Mainly, two types of methodologies have been adopted, namely interface tracking and interface capturing methods [21][22][23][24][25][26][27][28][29][30][31][32].…”

Section: Review On Numerical and Thermodynamic Models For Two-phase Flowsmentioning

confidence: 99%

Towards Understanding the Structure of Subcritical and Transcritical Liquid–Gas Interfaces Using a Tabulated Real Fluid Modeling Approach

et al. 2021

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A fundamental understanding and simulation of fuel atomization, phase transition, and mixing are among the topics researchers have struggled with for decades. One of the reasons for this is that the accurate, robust, and efficient simulation of fuel jets remains a challenge. In this paper, a tabulated multi-component real-fluid model (RFM) is proposed to overcome most of the limitations and to make real-fluid simulations affordable. Essentially, a fully compressible two-phase flow and a diffuse interface approach are used for the RFM model, which were implemented in the CONVERGE solver. PISO and SIMPLE numerical schemes were modified to account for a highly coupled real-fluid tabulation approach. These new RFM model and numerical schemes were applied to the simulation of different fundamental 1-D, 2-D, and 3-D test cases to better understand the structure of subcritical and transcritical liquid–gas interfaces and to reveal the hydro-thermodynamic characteristics of multicomponent jet mixing. The simulation of a classical cryogenic injection of liquid nitrogen coaxially with a hot hydrogen jet is performed using thermodynamic tables generated by two different equations of state: Peng–Robinson (PR) and Soave–Redlich–Kwong (SRK). The numerical results are finally compared with available experimental data and published numerical studies with satisfactory agreement.

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Section: Review On Numerical and Thermodynamic Models For Two-phase Flowsmentioning

confidence: 99%

Towards Understanding the Structure of Subcritical and Transcritical Liquid–Gas Interfaces Using a Tabulated Real Fluid Modeling Approach

et al. 2021

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“…[17], Concli and Gorla [6], Liu et al [24,25], and Mastrone et al [30]. Within the presented studies, simulated no-load losses were compared with experimental measurements whereby a good accordance is stated.…”

Section: Introductionmentioning

confidence: 76%

CFD analysis on the oil flow of a gear stage with guide plate

Hildebrand

Dangl

Sedlmair

et al. 2021

Forsch Ingenieurwes

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Gearbox housing geometry and oil guide plates strongly influence gearbox oil flow and interaction of oil with machine elements. Guided oil flow can increase gearbox efficiency and improve heat management. Recent research studies have demonstrated the potential of Computational Fluid Dynamics (CFD) simulations to predict the gearbox oil flow and no-load losses. Thereby, the influence of housing geometry and guide plates has rarely been addressed. This study focuses on a CFD analysis on the oil flow of a dip lubricated spur gear stage with a guide plate. Grid-based CFD models with different simulation setups were confronted and evaluated. Results show that the selection of the simulation setup with respect to the acceleration ramp and mesh size needs to address the considered object of investigation and the desired depth of information. An appropriate simulation setup shows great accordance with recordings of the oil distribution by a high-speed camera. A detailed analysis of the simulation results identified the contribution of different gear surface zones to the no-load gear loss torque. For the considered guide plate a strong interaction of oil flow and loss torque due to pressure forces on the tooth flank surface zones and due to shear forces on the front and tip circle surface zones of the gears was determined.

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“…The authors have applied different CFD approaches to study the efficiency of gearboxes. In particular, the global remeshing approach (Concli and Gorla, 2013;Concli, 2017;Mastrone et al, 2020) was exploited to study mating gears and planetary configurations, while the multiple reference frame and the sliding mesh approaches (Concli et al, 2015) were applied to helical and spur gears. Available studies on spiral bevel gears can be found in Webb et al (2010), who investigated the windage losses of a single gear.…”

Section: Introductionmentioning

confidence: 99%

Power Losses of Spiral Bevel Gears: An Analysis Based on Computational Fluid Dynamics

Mastrone

Concli

2021

Front. Mech. Eng.

Self Cite

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Energy efficiency is among the predominant aspects in mechanical design. Geared transmissions are widespread in several industrial applications and efficiency's improvements translate into various benefits, e.g., reduction of pollutants' emissions, better system's reliability due to lower operating temperatures, and higher power density. The possibility to compare different solutions in the preliminary stages of the design phase plays a determinant role to the achievements of these targets. In particular, Computational Fluid Dynamics (CFD) can be adopted to analyze the problem of interest overcoming the limitations of the analytical equations. On the other side, the application of numerical models to gears, in which the topology of the domain changes during operation, represents a challenging task and tailored mesh handling algorithms must be implemented. In the current paper, the power losses of a spiral bevel gear were examined numerically with an opensource tool. The predictions of the numerical models were compared with experimental data. The approach adopted shows a good computational effort making it useful for parametrical studies and, therefore, suggests being an effective tool for the analysis of the gearboxes' efficiency and lubrication.

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Oil distribution and churning losses of gearboxes: Experimental and numerical analysis

Cited by 53 publications

References 28 publications

Towards Understanding the Structure of Subcritical and Transcritical Liquid–Gas Interfaces Using a Tabulated Real Fluid Modeling Approach

Towards Understanding the Structure of Subcritical and Transcritical Liquid–Gas Interfaces Using a Tabulated Real Fluid Modeling Approach

CFD analysis on the oil flow of a gear stage with guide plate

Power Losses of Spiral Bevel Gears: An Analysis Based on Computational Fluid Dynamics

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