Influence of the Dynamic Motion of a Splash-Lubricated Gearbox on Churning Power Losses

Abstract

To investigate the influence of the dynamic motion of a gearbox on lubricating flow field and churning power losses under splash lubrication, a computational fluid dynamics (CFD) method based on a combination of the fluid of volume (VOF) method and turbulence model is presented in this paper. A non-inertial coordinate system was employed to simulate the motion of the gearbox, and the feasibility and accuracy of the method was validated by the available experimental results. Numerical models of the gearbox with a spur gear pair under no load operation condition were established, and sinusoidal motions with different frequencies and amplitudes were implemented in the gearbox. The effects of the rotational speed of gears, oil immersion depth, and the frequency and amplitude of sinusoidal motions were studied. The results showed that the dynamic motion of the gearbox can exert a significant influence on churning losses and the oil supply of the gear contacting zone, and the gear pair may be in a loss-of-lubrication state.