Abstract
The VOF (volume of fluid) multiphase transient simulation model of the windage loss of the gear pair under oil-jet lubrication was carried out by using the dynamic mesh technology with the powerful parallel computing capabilities of the Super Cloud Computing Center. Firstly, a two-phase (oil-gas) turbulence numerical model was established in the process of oil-jet lubrication. The numerical simulation test was designed by orthogonal experiment. The influence of the oil-jet lubrication parameters and their interaction on the windage power loss was studied by means of variance analysis. The results showed that the influence of injection speed on the windage power loss was the largest and proportional, followed by injection temperature and injection pressure, and the latter two factors were inversely proportional. Then, the fitting calculation formula of windage loss related to each influencing factor is obtained based on the numerical simulation results. Furthermore, by observing the velocity vector distribution of the internal flow field of the gearbox with different time, the formation mechanism of windage loss is understood intuitively, and the measures to reduce windage loss are put forward. Finally, the mechanical and energy characteristics of the windage loss under different oil injection parameters are proposed, by analyzing and calculating the differential pressure force, viscous force, turbulent kinetic energy, and turbulent dissipation rate around the gear pair. This paper provides a method guidance for the calculation of windage power loss and efficiency of aviation gear pair under elastohydrodynamic lubrication in engineering application.
Highlights
Oil supply for lubrication and cooling is necessary for aeroengine transmission gears, and it is because the gears have heavy-load and high-speed conditions
Since the fluid is viscous, it interacts with the rotating gear to cause windage loss, which consumes the gear transmission power, reducing the transmission efficiency of the gear system [1]
The results show that there is coupling interaction during both gear engagement, the deputy total windage loss of the gear pair is approximately equal to the sum of the two gears when they are not engaged
Summary
Oil supply for lubrication and cooling is necessary for aeroengine transmission gears, and it is because the gears have heavy-load and high-speed conditions (pitch velocity up to 100 m/s). Different approaches are available to calculate the windage losses of the oil-jet lubricated aviation pinion-gear pairs These are as follows: 1 measurements on test rigs, 2 calculation with empirical equations, and 3 simulation with computational fluid dynamics (CFD). The results verified that CFD numerical simulation is an effective tool for predicting the windage power losses It is one of the experimental works of realizing the visualization of the flow field near the highspeed gear by PIV technology for the first time. Tommaso et al [20] developed an adaptive mesh method that allowed automatic refinement and/or coarsening of the mesh at the air-oil interface He conducted a detailed numerical study on the radial impact of an oil injection jet on a single spur gear using the fluid volume (VOF) model and obtained the influence law of the oil-jet angle on windage torque and lubrication performance. In order to solve the problem of computing resource, this paper uses the powerful parallel computing capacity of the Super Cloud Computing Center to conduct multiphase transient emulation, with an average of 3 days to complete a result
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