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浙江大学学报(工学版)
Journal of ZheJiang University (Engineering Science)  2021, Vol. 55 Issue (5): 875-886    DOI: 10.3785/j.issn.1008-973X.2021.05.008
    
Flow field distribution of splash lubrication of gearbox and churning gear torque loss
Huan-long LIU1,2(),Chi-xin XIE1,2,Da-fa LI1,2,Jia-wei WANG1,2
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
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Abstract  

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.

Key words： splash lubrication      moving particle semi-implicit method (MPS)      flow field distribution      torque loss      computational fluid dynamics (CFD)     
Received: 28 April 2020      Published: 10 June 2021
CLC:  U 273.1  
Fund:  四川省科技厅重点研发资助项目（2018GZ0450）
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Huan-long LIU
Chi-xin XIE
Da-fa LI
Jia-wei WANG
Cite this article:

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.

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http://www.zjujournals.com/eng/10.3785/j.issn.1008-973X.2021.05.008     OR     http://www.zjujournals.com/eng/Y2021/V55/I5/875


齿轮箱飞溅润滑流场分布和搅油力矩损失

齿轮箱飞溅润滑具有齿轮旋转、两相流及流场分布复杂等特点，难以通过理论或实验进行研究；在计算流体动力学方法上，传统的网格法存在动网格处理困难、计算成本高的弊端.针对以上问题，提出运用移动粒子半隐式法(MPS)对齿轮箱飞溅润滑开展仿真分析. 在低转速时，设置不同润滑油型号和温度工况，发现润滑油流场分布情况与试验结果较一致. 在高转速时，设置不同的油温工况，发现相对光滑粒子流体动力学方法(SPH)，基于MPS方法数值计算所得的齿轮搅油力矩损失准确度更高，能够准确预测力矩损失变化趋势，但力矩损失预测误差较大，须进一步改进和完善. MPS方法严格保证了流体的不可压缩性，易于追踪捕捉大变形和强非线性化的自由液面，能够较好地分析预测齿轮箱飞溅润滑流场的分布效果.


关键词： 飞溅润滑,  移动粒子半隐式法（MPS）,  流场分布,  力矩损失,  计算流体动力学（CFD） 
Fig.1 Schematic diagram of MPS gradient model
Fig.2 MPS boundary particle layout
参数 ${m_{\rm{n}}}$/mm $a$/mm $b$/mm ${\alpha _{\rm{n}}}$/(°) ${\;\beta _0}$/(°) $z$/个 ${d_{\rm{a}}}$/mm $x$
主动轮 4.5 91.5 14 20 0 16 82.45 0.182
从动轮 4.5 91.5 14 20 0 24 118.35 0.171
Tab.1 Geometric parameters of FZG C-PT gear
Fig.3 Schematic diagram of FZG gear testing rig
工况 ${n_{\rm{o}}}$ /(r·min?1) 润滑油型号 $\theta $ /℃ $h$ /mm
1 240 FVA3 40 ?32.2
2 360 FVA3 40 ?32.2
3 540 FVA3 40 ?32.2
4 240 FVA3 100 ?32.2
5 360 FVA3 100 ?32.2
6 540 FVA3 100 ?32.2
7 240 FVA2 40 ?32.2
8 360 FVA2 40 ?32.2
9 540 FVA2 40 ?32.2
Tab.2 Low 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.3 High 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.4 Density and viscosity of different types of lubricants
Fig.4 Geometric 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.5 Computational time of gearbox splash lubrication under different operating conditions
$h$/mm 粒子数/个
?32.2 565538
?20.0 383103
Tab.6 Number 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.7 Basic parameters of SPH numerical simulation
Fig.5 Oil distribution of gearbox splash lubrication
Fig.6 Comparison of simulation and test of gearbox splash lubrication with FVA3 lubricant
Fig.7 Comparison of simulation and test of gearbox splash lubrication with FVA3 lubricant
Fig.8 Distribution of velocity field of gearbox splash lubrication under different operating conditions
Fig.9 Time domain curve of gear churning torque loss at 1444 r/min
Fig.10 Comparison of test and MPS simulated gear churning torque loss at 1444 r/min
Fig.11 Comparison 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.8 Errors of test and simulated gear churning torque loss under different operating conditions
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