Challenges and Solutions to Visualize and Study the Oil Flow Pattern inside Gear Quenching Tank Using CFD Methods

Abstract

Abstract As Computational Fluid Dynamics (CFD) methods evolve and mature, more engineering problems are being solved through computer simulation to reduce reliance on the costly and time-consuming experimental methods. This trend is also occurring in the gear manufacturing industry, where an increasing number of quality issues related to the oil quenching process are being investigated by CFD methods to find solutions. However, while the CFD theory and numerical methods have made significant advancements, gaps still exist between the academic research and industrial applications. In the case of the oil quenching processes, the prospect of using CFD methods to visualize and study the oil flow pattern in the gear quenching tank is promising yet challenging. The obstacle to simulating the oil quenching process using CFD methods lies not in the numerical method itself for solving the Navier-Stokes equation, but in building a computer simulation model that encompasses all the geometrical details of the quenching tank, fixtures, centrifugal pumps, and gears, including all the gear teeth. This task is particularly challenging for Finite Volume Method (FVM) CFD solvers, as the computation mesh could take days or weeks to build. In this research, a new solution method based on Smoothed Particle Hydrodynamics (SPH) is introduced to simulate the oil flow in the gear quenching tank. Since SPH is a mesh-free Lagrangian method, it not only greatly simplifies the mesh generation task for building the computational models but also handles the complex physics of the free surface flow and fluid-structure interaction with great ease. In addition, the oil flow in the gear quenching tank usually is driven by centrifugal pumps whose dynamics can be simulated directly in SPH methods, as opposed to FVM methods which require complicated moving mesh computation.