CFD-simulation of no-load power losses and the oil distribution of spur gears

空载齿轮功率损失在高速齿轮的主要损失中占有相当大的比例。目前，还没有有效的方法来量化这些损失。目前，使用经验公式，尽管这些公式只能提供粗略的近似值。空载齿轮损耗受齿轮箱中电流条件的影响。同样，没有有效的方法来预测这些条件。因此，阻碍了齿轮传动的开发和优化。精确而高效的预测方法可以显著提高齿轮工程效率优化的效率。作为经验方程的替代方法，最有前途的方法是使用计算流体动力学。该项目的主要目的是基于SPH方法开发优化和验证的CFD仿真模型，以预测齿轮传动中的空载齿轮损失和油分布。空载损失的结果将通过测量进行验证，而模拟的油分布将与高速摄像机的记录进行比较。在与慕尼黑工业大学机械元件研究所和空气动力学与流体力学研究所的合作中，将优化基于相互作用的SPH方法，并将其与体积法进行比较。这两种方法已经被两个研究所用于类似的应用。从数值的角度来看，SPH方法已经显示出巨大的潜力。通过在项目结束时将结果与货币量法进行比较，将建立一个既定的评估基础。本研究将探讨应用SPH方法预测齿轮传动的空载损失与油液分布的可能性，并探讨CFD在齿轮箱模拟研究领域的应用潜力，以减少未来耗时且昂贵的实验研究。

No-load gear power losses account for a considerable proportion of the main losses in high-speed gears. Currently, there is no efficient method to quantify these losses. At present, em-pirical equations are used, despite these formulas could just provide roughly approximated values. No-load gear losses are affected by the current flow conditions in the gearbox. Again, there is no efficient method to predict these conditions. Consequently, the development orthe optimization of geared transmissions is impeded. The efficiency optimization in gear en-gineering could be remarkably improved by a precise and yet efficient predicting method. As an alternative to empirical equations, the most promising method is the use of computational fluid dynamics. The main aim of the proposed project is the development of an optimized and validated CFD simulation model based on the SPH method in order to predict the no-load gear losses and the oil distribution in geared transmissions. The results for the no-load losses will be validated by the measurements, whereas the simulated oil distribution is compared to the recordings made by a high-speed camera.In collaboration with the Institute of Machine Elements and the Institute of Aerodynamics and Fluid Mechanics of the Technical University of Munich, the interaction based SPH method will be optimized and compared to the Finite-Volume Method. Both methods have already been used by both institutes for similar applications.It has already been shown that the SPH method has great potential from a numerical point of view. By comparing the results with the Finite-Volume Method at the end of the project, an established base of evaluation will be created. The possibility of applying the SPH method for the prediction of no-load losses and the oil distribution in geared transmissions will be explored.In this project, potentials of CFD applications in the research field of gearbox simulation will be detected, which can reduce the time consuming and expensive experimental investigations in the future.