Optimal Design of Computational Fluid Dynamics: Numerical Calculation and Simulation Analysis of Windage Power Losses in the Aviation

Abstract

Based on the theory of computational fluid dynamics (CFD), with the help of the Fluent software and the powerful parallel computing capability of the super cloud computer, the single-phase flow transient simulation calculation of the windage power loss of the engagement spiral bevel gear pair (SBGP) was performed. The two-equation SST k-ω turbulence model based on the assumption of eddy viscosity was adopted, which was improved from the standard k-ε model combined with the Wilcox k-ω model. The SST k-ω turbulence model inherited the respective advantages of the Wilcox k-ω model in the near-wall region and the k-ε model in the free shear layer and could more accurately describe the resistance and separation effect of the gear tooth surface on the airflow. The simulation analyzed the airflow characteristics around SBGP and the mechanism of the windshield to reduce the windage loss of the gear. It also studied the influence of the windshield clearance and opening size on the windage power loss. Then the orthogonal experimental analysis method was adopted to perform numerical simulation analysis. The windage torque was studied under different clearance values between the windshield and the gear tooth surface, as well as the large end and the small end. The variance analysis was performed on the numerical simulation data. The results showed that when the windshield clearance value was 1 mm and the engagement opening was 30°, the windage torque was the smallest, and the effect of reducing the windage power loss was the best. According to the changes in the pressure, velocity, and turbulent kinetic energy cloud diagram of the flow field in the reducer during multi-group simulation tests, the local optimal windshield configuration was obtained, which provided a method for further research on the multi-objective optimization of the windshield and the windage loss of the gear pair under the oil–gas two-phase flow and also provided a reference for the practical engineering application of the windshield.