Pumping Loss of Shrouded Meshed Spur Gears

2020 ◽  
Author(s):  
Michael J. Hurrell ◽  
Jerzy T. Sawicki
Keyword(s):  
High Speed ◽  
Fluid Dynamic ◽  
Spur Gear ◽  
Test Facility ◽  
Spur Gears ◽  
Cfd Analysis ◽  
Total Load ◽  
New Approach ◽  
Loss Component ◽  
Swept Volume

Abstract High speed rotorcraft transmissions are subject to load-independent power losses consisting of drag loss and pumping loss. Tightly conforming shrouds enclosing the transmission gears are often incorporated to reduce the drag component of the total load-independent losses. However, tightly conforming axial shrouds can result in an increase in the pumping loss component. Quantifying the pumping loss of shrouded gear transmissions has been the subject of many studies. This study presents a new approach for estimating pumping loss based on the concept of swept volume and examines the applicability of the approach to various shroud configurations. The drag loss and pumping loss of a shrouded spur gear pair has been determined through testing using the NASA Glenn Research Center (GRC) Gear Windage Test Facility. The results from this testing have been compared to theoretical results using the formulations presented in this study. In addition, computational fluid dynamic (CFD) analysis has been conducted for the various shroud configurations tested at NASA GRC. The results from the CFD analysis confirm the theoretical and empirical results and provide insight into the applicability of the swept volume approach for estimating pumping power loss of shrouded gear transmissions.

Pumping Loss of Shrouded Meshed Spur Gears

2020 ◽  
Vol 142 (11) ◽  
Author(s):  
Michael J. Hurrell ◽  
Jerzy T. Sawicki
Keyword(s):  
High Speed ◽  
Spur Gear ◽  
Test Facility ◽  
Spur Gears ◽  
Cfd Analysis ◽  
Total Load ◽  
New Approach ◽  
Computational Fluid Dynamics Cfd ◽  
Loss Component ◽  
Swept Volume

Abstract High speed rotorcraft transmissions are subject to load-independent power losses consisting of drag loss and pumping loss. Tightly conforming shrouds enclosing the transmission gears are often incorporated to reduce the drag component of the total load-independent losses. However, tightly conforming axial shrouds can result in an increase in the pumping loss component. Quantifying the pumping loss of shrouded gear transmissions has been the subject of many studies. This study presents a new approach for estimating pumping loss based on the concept of swept volume and examines the applicability of the approach to various shroud configurations. The drag loss and pumping loss of a shrouded spur gear pair have been determined through testing using the NASA Glenn Research Center (GRC) Gear Windage Test Facility. The results from this testing have been compared to theoretical results using the formulations presented in this study. In addition, computational fluid dynamics (CFD) analysis has been conducted for the various shroud configurations tested at NASA GRC. The results from the CFD analysis confirm the theoretical and empirical results and provide insight into the applicability of the swept volume approach for estimating pumping power loss of shrouded gear transmissions.

Three-Dimensional CFD Analysis of Meshing Losses in a Spur Gear Pair

2018 ◽  
Author(s):  
T. Fondelli ◽  
D. Massini ◽  
A. Andreini ◽  
B. Facchini ◽  
F. Leonardi
Keyword(s):  
High Speed ◽  
Numerical Study ◽  
Fluid Dynamic ◽  
Three Dimensional ◽  
Spur Gear ◽  
Computational Domain ◽  
Gear Pair ◽  
Transient Pressure ◽  
Numerical Effort ◽  
Free Environment

The reduction of fluid-dynamic losses in high speed gearing systems is nowadays increasing importance in the design of innovative aircraft propulsion systems, which are particularly focused on improving the propulsive efficiency. Main sources of fluid-dynamic losses in high speed gearing systems are windage losses, inertial losses resulting by impinging oil jets used for jet lubrication and the losses related to the compression and the subsequent expansion of the fluid trapped between gears teeth. The numerical study of the latter is particularly challenging since it faces high speed multiphase flows interacting with moving surfaces, but it paramount for improving knowledge of the fluid behavior in such regions. The current work aims to analyze trapping losses in a gear pair by means of three-dimensional CFD simulations. In order to reduce the numerical effort, an approach for restricting computational domain was defined, thus only a portion of the gear pair geometry was discretized. Transient calculations of a gear pair rotating in an oil-free environment were performed, in the context of conventional eddy viscosity models. Results were compared with experimental data from the open literature in terms of transient pressure within a tooth space, achieving a good agreement. Finally, a strategy for meshing losses calculation was developed and results as a function of rotational speed were discussed.

Bending Fatigue Tests of High Speed Spur Gears

1981 ◽  
Vol 103 (2) ◽  
pp. 466-473 ◽  
Author(s):  
I. Yuruzume ◽  
H. Mizutani
Keyword(s):  
High Speed ◽  
Normal Load ◽  
Load Capacity ◽  
Spur Gear ◽  
Fatigue Tests ◽  
Spur Gears ◽  
Bending Fatigue ◽  
Tooth Width ◽  
Bending Load ◽  
Bending Fatigue Strength

Effects of addendum modification of tooth profiles on the bending fatigue strength of high speed spur gear are discussed in this presentation: A JIS Class O Spur gear of m3, α20 deg, Z1 27, and made of AMS 6260 (AISI 9310) steel precisely ground after carburizing and hardening was meshed with the other gear of Z2 77 and operated at 8550 rpm. In this running test, bending load capacity and running performance comparisons between the gear with standard tooth profile and the two shifted gears of which tooth addendum modification coefficients were 0.35 and 0.8. The maximum normal load of the gear with addendum modification coefficient 0.8 at 107 (10 million) cycles was 1.8 kNsmm per unit tooth width. The maximum Hertz stress of this gear was 2.43 × 109 Nsm2. The allowable normal load of the gear with 0.8 was higher than that of the standard gear by 87 percent and higher than of the 0.35 profile shifted gears by 20 percent.

scholarly journals Study of Lubricant Jet Flow Phenomena in Spur Gears

1975 ◽  
Vol 97 (2) ◽  
pp. 283-288 ◽  
Author(s):  
L. S. Akin ◽  
J. J. Mross ◽  
D. P. Townsend
Keyword(s):  
Motion Picture ◽  
High Speed ◽  
Drop Size ◽  
Gear Tooth ◽  
Jet Flow ◽  
Spur Gear ◽  
Spur Gears ◽  
Gear Teeth ◽  
Flow Phenomena ◽  
Oil Jet

Lubricant jet flow impingement and penetration depth into a gear tooth space were measured at 4920 and 2560 using a 8.89-cm- (3.5-in.) pitch dia 8 pitch spur gear at oil pressures from 7 × 104 to 41 × 104 N/m2 (10 psi to 60 psi). A high speed motion picture camera was used with xenon and high speed stroboscopic lights to slow down and stop the motion of the oil jet so that the impingement depth could be determined. An analytical model was developed for the vectorial impingement depth and for the impingement depth with tooth space windage effects included. The windage effects on the oil jet were small for oil drop size greater than 0.0076 cm (0.003 in.). The analytical impingement depth compared favorably with experimental results above an oil jet pressure of 7 × 104 N/m2 (10 psi). Some of this oil jet penetrates further into the tooth space after impingement. Much of this post impingement oil is thrown out of the tooth space without further contacting the gear teeth.

Dynamic Transmission Error Measurements From Spur Gear Pairs Having Tooth Indexing Errors

2017 ◽  
Author(s):  
Brian Anichowski ◽  
Ahmet Kahraman ◽  
David Talbot
Keyword(s):  
High Speed ◽  
Transient Behavior ◽  
Transmission Error ◽  
Spur Gear ◽  
Spur Gears ◽  
Transient Effects ◽  
Dynamic Factors ◽  
Frequency Domains ◽  
Error Dynamic ◽  
Dynamic Transmission Error

This paper complements recent investigations [Handschuh et al (2014), Talbot et al (2016)] of the influences of tooth indexing errors on dynamic factors of spur gears by presenting data on changes to the dynamic transmission error. An experimental study is performed using an accelerometer-based dynamic transmission error measurement system incorporated into a high-speed gear tester to establish baseline dynamic behavior of gears having negligible indexing errors, and to characterize changes to this baseline due to application of tightly-controlled intentional indexing errors. Spur test gears having different forms of indexing errors are paired with a gear having negligible indexing error. Dynamic transmission error of gear pairs under these error conditions is measured and examined in both time and frequency domains to quantify the transient effects induced by these indexing errors. Both measurements indicate clearly that the baseline dynamic response, dominated by well-defined resonance peaks and mesh harmonics, are complemented by non-mesh orders of transmission error due the transient behavior induced by indexing errors.

Axial Load Control on High-Speed Turbochargers: Test and Prediction

2008 ◽  
Author(s):  
Kostandin Gjika ◽  
Gerald D. LaRue
Keyword(s):  
Axial Load ◽  
High Speed ◽  
Control Volume ◽  
Fluid Dynamic ◽  
Test Facility ◽  
Load Control ◽  
Lateral Motion ◽  
Radial Vibrations ◽  
Axial Thrust ◽  
Thrust Load

This paper deals with axial thrust load control in high-speed turbochargers. A specific test facility was developed to demonstrate the feasibility of axial load measurement and control. A special turbocharger was developed and instrumented to measure axial load and other test parameters. The axial load was controlled by throttling the compressor inlet and/or outlet flow. Extensive testing and analysis during both steady state and transient behavior conditions were completed on a special test bench. A thrust load map was developed and superimposed on the compressor map, and the relationship between turbocharger aerodynamics performance and axial thrust load was identified. During testing, the interaction between axial load, rotating group lateral motion and radial vibrations on the turbocharger housing was also identified. Running the turbocharger with low axial load shows no major problems on rotating group lateral motion or oil leakage. An analytical approach using a control volume type fluid dynamic model and a prediction code for axial thrust load has been developed. It shows good agreement between measured and predicted thrust load.

scholarly journals Standardization of Malaysian Adult Female Nasal Cavity

2013 ◽  
Vol 2013 ◽  
pp. 1-11 ◽  
Author(s):  
Chih Fang Lee ◽  
Mohd. Zulkifly Abdullah ◽  
Kamarul Arifin Ahmad ◽  
Ibrahim Lutfi Shuaib
Keyword(s):  
Nasal Cavity ◽  
Average Velocity ◽  
Fluid Dynamic ◽  
Cfd Analysis ◽  
Sectional Area ◽  
Cavity Model ◽  
Cross Sectional ◽  
New Approach ◽  
Nasal Cavities ◽  
Preliminary Study

This research focuses on creating a standardized nasal cavity model of adult Malaysian females. The methodology implemented in this research is a new approach compared to other methods used by previous researchers. This study involves 26 females who represent the test subjects for this preliminary study. Computational fluid dynamic (CFD) analysis was carried out to better understand the characteristics of the standardized model and to compare it to the available standardized Caucasian model. This comparison includes cross-sectional areas for both half-models as well as velocity contours along the nasal cavities. The Malaysian female standardized model is larger in cross-sectional area compared to the standardized Caucasian model thus leading to lower average velocity magnitudes. The standardized model was further evaluated with four more Malaysian female test subjects based on its cross-sectional areas and average velocity magnitudes along the nasal cavities. This evaluation shows that the generated model represents an averaged and standardized model of adult Malaysian females.

scholarly journals CFD analysis on the oil flow of a gear stage with guide plate

2021 ◽  
Author(s):  
Lucas Hildebrand ◽  
Florian Dangl ◽  
Martin Sedlmair ◽  
Thomas Lohner ◽  
Karsten Stahl
Keyword(s):  
High Speed ◽  
Mesh Size ◽  
Spur Gear ◽  
Cfd Analysis ◽  
Heat Management ◽  
Cfd Models ◽  
Guide Plate ◽  
Oil Flow ◽  
Tooth Flank ◽  
Flank Surface

AbstractGearbox housing geometry and oil guide plates strongly influence gearbox oil flow and interaction of oil with machine elements. Guided oil flow can increase gearbox efficiency and improve heat management. Recent research studies have demonstrated the potential of Computational Fluid Dynamics (CFD) simulations to predict the gearbox oil flow and no-load losses. Thereby, the influence of housing geometry and guide plates has rarely been addressed. This study focuses on a CFD analysis on the oil flow of a dip lubricated spur gear stage with a guide plate. Grid-based CFD models with different simulation setups were confronted and evaluated. Results show that the selection of the simulation setup with respect to the acceleration ramp and mesh size needs to address the considered object of investigation and the desired depth of information. An appropriate simulation setup shows great accordance with recordings of the oil distribution by a high-speed camera. A detailed analysis of the simulation results identified the contribution of different gear surface zones to the no-load gear loss torque. For the considered guide plate a strong interaction of oil flow and loss torque due to pressure forces on the tooth flank surface zones and due to shear forces on the front and tip circle surface zones of the gears was determined.

Experimental and Numerical Investigation on Windage Power Losses in High Speed Gears

2017 ◽  
Author(s):  
D. Massini ◽  
T. Fondelli ◽  
A. Andreini ◽  
B. Facchini ◽  
L. Tarchi ◽  
...  
Keyword(s):  
High Speed ◽  
Power Transmission ◽  
Fluid Dynamic ◽  
Spur Gear ◽  
Cooling Capacity ◽  
Relative Magnitude ◽  
Power Losses ◽  
Test Rig ◽  
Aero Engines ◽  
Cooling And Lubrication

Enhancing the efficiency of gearing systems is an important topic for the development of future aero-engines with low specific fuel consumption. The transmission system in fact has a direct impact on the engine overall efficiency by means of its weight contribution, internal power losses and lubrication requirements. Thus, an evaluation of its structure and performance is mandatory in order to optimize the design as well as maximize its efficiency. Gears are among the most efficient power transmission systems, whose efficiencies can exceed 99 %, nevertheless in high speed applications power losses are anything but negligible. All power dissipated through losses is converted into heat that must be dissipated by the lubrication system. More heat leads to a larger cooling capacity, which results in more oil, larger heat exchangers which finally means more weight. Mechanical power losses are usually distinguished in two main categories: load-dependent and load-independent losses. The former are all those associated with the transmission of torque, while the latter are tied to the fluid-dynamics of the environment which surrounds the gears, namely windage, fluid trapping and squeezing between meshing gear teeth and inertial losses resulting by the impinging oil jets, usually adopted in high speed transmission for cooling and lubrication purposes. The relative magnitude of these phenomena is strongly dependent on the operative conditions of the transmission. While load-dependent losses are predominant at slow speeds and high torque conditions, load-independent mechanisms become prevailing in high speed applications, like in turbomachinery. Among fluid-dynamic losses, windage is extremely important and can dominate the other mechanisms. In this context, a new test rig was designed for investigating windage power losses resulting by a single spur gear rotating in a free oil environment. The test rig allows the gear to rotate at high speed within a box where pressure and temperature conditions can be set and monitored. An electric spindle, which drives the system, is connected to the gear through a high accuracy torque meter, equipped with a speedometer providing the rotating velocity. The test box is fitted with optical accesses in order to perform particle image velocimetry measurements for investigating the flow-field surrounding the rotating gear. The experiment has been computationally replicated, performing RANS simulations in the context of conventional eddy viscosity models. The numerical results were compared with experimental data in terms of resistant torque as well as PIV measurements, achieving a good agreement for all of the speed of rotations.

CFD Analysis of Gear Windage Losses: Validation and Parametric Aerodynamic Studies

2011 ◽  
Vol 133 (3) ◽  
Author(s):  
Matthew J. Hill ◽  
Robert F. Kunz ◽  
Richard B. Medvitz ◽  
Robert F. Handschuh ◽  
Lyle N. Long ◽  
...  
Keyword(s):  
Experimental Data ◽  
Spur Gear ◽  
Mitigation Strategies ◽  
Test Facility ◽  
Cfd Analysis ◽  
Physical Mechanisms ◽  
Computational Fluid Dynamics Cfd ◽  
Cfd Method ◽  
Cfd Analyses ◽  
Good Agreement

A computational fluid dynamics (CFD) method has been applied to gear configurations with and without shrouding. The goals of this work have been to validate the numerical and modeling approaches used for these applications and to develop physical understanding of the aerodynamics of gear windage loss. Several spur gear geometries are considered, for which experimental data are available. Various canonical shrouding configurations and free spinning (no shroud) cases are studied. Comparisons are made with experimental data from open literature, and data recently obtained in the NASA Glenn Research Center Gear Windage Test Facility, Cleveland, OH. The results show good agreement with the experiment. The parametric shroud configuration studies carried out in the Glenn experiments and the CFD analyses elucidate the physical mechanisms of windage losses as well as mitigation strategies due to shrouding and newly proposed tooth contour modifications.

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