1. Engineering Research Center of Advanced Driving Energy-saving Technology, Ministry of Education, Chengdu 610031, China 2. School of Mechanical Engineering, Southwest Jiaotong University, Chengdu 610031, China
Gearbox splash lubrication has the characteristics of gear rotation, two-phase flow and complex flow field distribution, which is difficult to study through theory or experiment. In terms of computational fluid dynamics, the traditional grid method has the disadvantages of difficulty in processing dynamic grids and high computational cost. In view of the above problems, the moving particle semi-implicit method (MPS) was used to carry out the simulation analysis of the gearbox splash lubrication. At low speeds, different lubricating oil models and temperature conditions were set, and it was found that the lubricating oil flow field distribution was in good agreement with the test results. At high speeds, different oil temperature conditions were set, and it was found that compared with the smooth particle hydrodynamics method (SPH), the accuracy of the gear churning torque loss obtained by the MPS method was higher. It can accurately predict the trend of torque loss, but the error of torque loss prediction is relatively large, and further improvement and perfection are needed. The MPS method strictly guarantees the incompressibility of the fluid. It is easy to track and capture the free surface with large deformation and strong non-linearity The MPS method can be used to analyze and predict the distribution of splash lubrication flow field of the gearbox well.
Huan-long LIU,Chi-xin XIE,Da-fa LI,Jia-wei WANG. Flow field distribution of splash lubrication of gearbox and churning gear torque loss. Journal of ZheJiang University (Engineering Science), 2021, 55(5): 875-886.
Tab.2Low speed operating condition parameters of gearbox splash lubrication
工况
$\theta $ /℃
$h$ /mm
${n_{\rm{w}}}$ /(r·min?1)
润滑油型号
1
60
?20.0
1444
FVA3
2
60
?20.0
3474
FVA3
3
90
?20.0
1444
FVA3
4
90
?20.0
3474
FVA3
5
120
?20.0
1444
FVA3
6
120
?20.0
3474
FVA3
Tab.3High speed operating condition parameters of gearbox splash lubrication
型号
ISO VG
$\;\rho $/ (kg·m?3)
$\gamma $/(mm2·s?1)
θ=40 ℃
θ=60 ℃
θ=90 ℃
θ=100 ℃
θ=120 ℃
FVA3
100
864
95
40
15
10.7
5
FVA2
32
855
32
?
?
5.4
?
Tab.4Density and viscosity of different types of lubricants
Fig.4Geometric model of gearbox splash lubrication
低转速工况
${t_{\rm{s}}}$/h
高转速工况
${t_{\rm{s}}}$/h
1
140.2
1
23.6
2
76.7
2
14.7
3
61.0
3
26.2
4
153.3
4
17.1
5
85.3
5
30.1
6
42.3
6
19.5
7
171.4
?
?
8
101.1
?
?
9
90.1
?
?
Tab.5Computational time of gearbox splash lubrication under different operating conditions
$h$/mm
粒子数/个
?32.2
565538
?20.0
383103
Tab.6Number of particles in gearbox with splash lubrication at different liquid levels
${n_{\rm{w}}}$ /(r·min?1)
硬件
${d_{\rm{p}}}$/mm
${t_{\rm{p}}}$/s
$\Delta t$/s
${t_{\rm{s}}}$/h
1444
NVIDIA Tesla K40m
1.0
2
1.9×10?6
72
3474
NVIDIA Tesla K40m
1.0
2
9.1×10?7
92
Tab.7Basic parameters of SPH numerical simulation
Fig.5Oil distribution of gearbox splash lubrication
Fig.6Comparison of simulation and test of gearbox splash lubrication with FVA3 lubricant
Fig.7Comparison of simulation and test of gearbox splash lubrication with FVA3 lubricant
Fig.8Distribution of velocity field of gearbox splash lubrication under different operating conditions
Fig.9Time domain curve of gear churning torque loss at 1444 r/min
Fig.10Comparison of test and MPS simulated gear churning torque loss at 1444 r/min
Fig.11Comparison of test and MPS simulated gear churning torque loss at 3474 r/min
${n_{\rm{w}}}$/(r·min?1)
$\theta $/℃
${T_{\rm{m}}}$/(N·m)
${T_{\rm{s}}}$/(N·m)
${T_{\rm{e}}}$/(N·m)
${\delta _{\rm{m}}}$/%
${\delta _{\rm{s}}}$/%
1444
60
0.128
0.123
0.318
60
61
1444
90
0.106
0.098
0.297
64
67
1444
120
0.093
0.085
0.277
66
69
3474
60
0.307
0.261
0.584
47
55
3474
90
0.349
0.216
0.711
51
70
3474
120
0.650
0.199
1.130
43
82
Tab.8Errors of test and simulated gear churning torque loss under different operating conditions
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