scholarly journals CFD simulations of gearboxes: implementation of a mesh clustering algorithm for efficient simulations of complex system’s architectures

2021 ◽  
Vol 16 (1) ◽  
Author(s):  
Marco Nicola Mastrone ◽  
Franco Concli
Keyword(s):  
Clustering Algorithm ◽  
Computational Domain ◽  
Power Losses ◽  
Cfd Simulations ◽  
Bevel Gears ◽  
Engineering Problems ◽  
Virtual Prototypes ◽  
System Configurations ◽  
Determinant Factor ◽  
Simulation Time

AbstractIn the last decade, computer-aided engineering (CAE) tools have become a determinant factor in the analysis of engineering problems. In fact, they bring a clear reduction of time in the design phase of a new product thanks to parametrical studies based on virtual prototypes. The application of such tools to gearboxes allowed engineers to study the efficiency and lubrication inside transmissions. However, the difficulties of handling the computational domain are still a concern for complex system configurations. For this reason, the authors maintain that it is fundamental to introduce time efficient algorithms that enable the effective study of any kind of gear, e.g., helical and bevel configurations. In this work, a new mesh handling strategy specifically suited for this kind of studies is presented. The methodology is based on the Global Remeshing Approach with Mesh Clustering (GRAMC) process that drastically reduces the simulation time by minimizing the effort for updating the grids. This procedure was tested on spur, helical, and bevel gears, thus demonstrating the flexibility of the approach. The comparison with experimentally measured power losses highlighted the good accuracy of the strategy. The algorithm was implemented in the opensource software OpenFOAM®.

scholarly journals Computational Fluid Dynamics Applied to Lubricated Mechanical Components: Review of the Approaches to Simulate Gears, Bearings, and Pumps

2020 ◽  
Vol 10 (24) ◽  
pp. 8810
Author(s):  
Lorenzo Maccioni ◽  
Franco Concli
Keyword(s):  
Fluid Dynamics ◽  
Computational Fluid Dynamics ◽  
Mechanical Systems ◽  
Computational Domain ◽  
Power Losses ◽  
Cfd Simulations ◽  
Current State ◽  
Computational Fluid Dynamics Cfd ◽  
Mechanical Components ◽  
Complex Mechanical Systems

The lubrication of the mechanical components reduces friction, and increases the efficiency and the reliability. However, the interaction of moving components with the lubricant leads to power losses due to viscous and inertial effects. Nowadays, the study of lubricant behavior can be carried out through computational fluid dynamics (CFD) simulations. Nevertheless, the modeling of the computational domain within complex mechanical systems (e.g., ordinary, planetary and cycloidal gearboxes, roller bearings, and pumps) requires the exploitation of specific CFD techniques. In the last decades, many mesh-based or meshless approaches have been developed to deal with the complex management of the topological changes of the computational domain or the modeling of complex kinematics. This paper aims to collect and to classify the scientific literature where these approaches have been exploited for the study of lubricated mechanical systems. The goal of this research is to shed a light on the current state of the art in performing CFD analysis of these systems. Moreover, the objective of this study is to stress the limits and the capabilities of the main CFD techniques applied in this field of research. Results show the main differences in terms of accuracy achievable and the level of complexity that can be managed with the different CFD approaches.

scholarly journals A New Integrated Approach for the Prediction of the Load Independent Power Losses of Gears: Development of a Mesh-Handling Algorithm to Reduce the CFD Simulation Time

2016 ◽  
Vol 2016 ◽  
pp. 1-8 ◽  
Author(s):  
F. Concli ◽  
A. Della Torre ◽  
C. Gorla ◽  
G. Montenegro
Keyword(s):  
Prediction Models ◽  
Cfd Simulation ◽  
Integrated Approach ◽  
Numerical Approach ◽  
Computational Effort ◽  
Power Losses ◽  
Cfd Simulations ◽  
Numerical Calculation Method ◽  
Simulation Time ◽  
Potential Tool

To improve the efficiency of geared transmissions, prediction models are required. Literature provides only simplified models that often do not take into account the influence of many parameters on the power losses. Recently some works based on CFD simulations have been presented. The drawback of this technique is the time demand needed for the computation. In this work a less time-consuming numerical calculation method based on some specific mesh-handling techniques was extensively applied. With this approach the windage phenomena were simulated and compared with experimental data in terms of power loss. The comparison shows the capability of the numerical approach to capture the phenomena that can be observed experimentally. The powerful capabilities of this approach in terms of both prediction accuracy and computational effort efficiency make it a potential tool for an advanced design of gearboxes as well as a powerful tool for further comprehension of the physics behind the gearbox lubrication.

scholarly journals Optimising the computational domain size in CFD simulations of tall buildings

Heliyon ◽  
2021 ◽  
Vol 7 (4) ◽  
pp. e06723
Author(s):  
Yousef Abu-Zidan ◽  
Priyan Mendis ◽  
Tharaka Gunawardena
Keyword(s):  
Tall Buildings ◽  
Domain Size ◽  
Computational Domain ◽  
Cfd Simulations

Network modelling of dry-type transformer cooling systems

2018 ◽  
Vol 37 (3) ◽  
pp. 1039-1053 ◽  
Author(s):  
Andrea Cremasco ◽  
Wei Wu ◽  
Andreas Blaszczyk ◽  
Bogdan Cranganu-Cretu
Keyword(s):  
Network Model ◽  
Thermal Model ◽  
Cfd Simulation ◽  
Cooling System ◽  
Cfd Simulations ◽  
Network Modelling ◽  
Cooling Systems ◽  
Content Type ◽  
System Configurations ◽  
Dielectric Insulation

Purpose The application of dry-type transformers is growing in the market because the technology is non-flammable, safer and environmentally friendly. However, the unit dimensions are normally larger and material costs become higher, as no oil is present for dielectric insulation or cooling. At designing stage, a transformer thermal model used for predicting temperature rise is fundamental and the modelling of cooling system is particularly important. This paper aims to describe a thermal model used to compute dry transformers with different cooling system configurations. Design/methodology/approach The paper introduces a fast-calculating thermal and pressure network model for dry-transformer cooling systems, preliminarily verified by analytical methods and advanced CFD simulations, and finally validated with experimental results. Findings This paper provides an overview of the network model of dry-transformer cooling system, describing its topology and its main variants including natural or forced ventilation, with or without cooling duct in the core, enclosure with roof and floor ventilation openings and air barriers. Finally, it presents a formulation for the new heat exchanger element. Originality/value The network approach presented in this paper allows to model efficiently the cooling system of dry-type transformers. This model is based on physical principles rather than empirical assessments that are valid only for specific transformer technologies. In comparison with CFD simulation approach, the network model runs much faster and the accuracies still fall in acceptable range; therefore, one is able to utilize this method in optimization procedures included in transformer design systems.

scholarly journals On the Assessment of Numerical Wave Makers in CFD Simulations

2019 ◽  
Vol 7 (2) ◽  
pp. 47 ◽  
Author(s):  
Christian Windt ◽  
Josh Davidson ◽  
Pál Schmitt ◽  
John Ringwood
Keyword(s):  
Test Cases ◽  
Cfd Simulations ◽  
Wave Tank ◽  
Free Surface Waves ◽  
Offshore Engineering ◽  
Engineering Problems ◽  
Computational Fluid Dynamics Cfd ◽  
Single Method ◽  
Wave Maker ◽  
Numerical Wave

A fully non-linear numerical wave tank (NWT), based on Computational Fluid Dynamics (CFD), provides a useful tool for the analysis of coastal and offshore engineering problems. To generate and absorb free surface waves within a NWT, a variety of numerical wave maker (NWM) methodologies have been suggested in the literature. Therefore, when setting up a CFD-based NWT, the user is faced with the task of selecting the most appropriate NWM, which should be driven by a rigorous assessment of the available methods. To provide a consistent framework for the quantitative assessment of different NWMs, this paper presents a suite of metrics and methodologies, considering three key performance parameters: accuracy, computational requirements and available features. An illustrative example is presented to exemplify the proposed evaluation metrics, applied to the main NWMs available for the open source CFD software, OpenFOAM. The considered NWMs are found to reproduce waves with an accuracy comparable to real wave makers in physical wave tank experiments. However, the paper shows that significant differences are found between the various NWMs, and no single method performed best in all aspects of the assessment across the different test cases.

On the Validity and Sensitivity of CFD Simulations for a Deterministic Breaking Wave Impact on a Semi Submersible

2018 ◽  
Author(s):  
Henry Bandringa ◽  
Joop A. Helder
Keyword(s):  
Free Surface ◽  
Absorbing Boundary Conditions ◽  
Implicit Time ◽  
Breaking Wave ◽  
Computational Domain ◽  
Wave Impact ◽  
Time Step ◽  
Cfd Simulations ◽  
Detailed Model ◽  
Run Up

To assess the integrity and safety of structures offshore, prediction of run-up, green water, and impact loads needs to be made during the structure’s design. For predicting these highly non-linear phenomena, most of the offshore industry relies on detailed model testing. In the last couple of years however, CFD simulations have shown more and more promising results in predicting these events, see for instance [1]–[4]. To obtain confidence in the accuracy of CFD simulations in the challenging field of extreme wave impacts, a proper validation of such CFD tools is essential. In this paper two CFD tools are considered for the simulation of a deterministic breaking wave impact on a fixed semi submersible, resulting in flow phenomena like wave run-up, horizontal wave impact and deck impacts. Hereby, one of the CFD tools applies an unstructured gridding approach and implicit free-surface reconstruction, and uses an implicit time integration with a fixed time step. The other CFD tool explicitly reconstructs the free surface on a structured grid and integrates the free surface explicitly in time, using a variable time step. The presented simulations use a compact computational domain with wave absorbing boundary conditions and local grid refinement to reduce CPU time. Besides a typical verification and validation of the results, for one of the CFD tools a sensitivity study is performed in which the influence of small variations in the incoming breaking wave on the overall results is assessed. Such an analysis should provide the industry more insight in the to-be-expected sensitivity (and hence uncertainty) of CFD simulations for these type of applications. Experiments carried out by MARIN are used to validate all the presented simulation results.

Optimal Tooth Modifications in Face-Hobbed Spiral Bevel Gears to Reduce the Influence of Misalignments on Elastohydrodynamic Lubrication

2014 ◽  
Vol 136 (7) ◽  
Author(s):  
Vilmos V. Simon
Keyword(s):  
Carrying Capacity ◽  
Optimization Procedure ◽  
Load Carrying Capacity ◽  
Power Losses ◽  
Spiral Bevel Gears ◽  
Oil Film ◽  
Bevel Gears ◽  
Ehd Lubrication ◽  
Load Carrying ◽  
Spiral Bevel

In this study, an optimization methodology is proposed to systematically define the optimal tooth modifications introduced by head-cutter geometry and machine-tool settings to minimize the influence of misalignments on the elastohydrodynamic (EHD) lubrication characteristics in face-hobbed spiral bevel gears. The goal is to simultaneously maximize the EHD load-carrying capacity of the oil film and to minimize power losses in the oil film when different misalignments are inherent in the gear pair. The proposed optimization procedure relies heavily on the EHD lubrication analysis developed in this paper. The core algorithm of the proposed nonlinear programming procedure is based on a direct search method. Effectiveness of this optimization was demonstrated on a face-hobbed spiral bevel gear example. A drastic increase in the EHD load-carrying capacity of the oil film and a reduction in the power losses in the oil film were obtained.

Comparison of the CFD Results to PIV Measurements in Kinematics of Spilling and Plunging Breakers

2020 ◽  
Author(s):  
Bülent Düz ◽  
Jule Scharnke ◽  
Rink Hallmann ◽  
Jan Tukker ◽  
Siddhant Khurana ◽  
...  
Keyword(s):  
High Speed ◽  
Piecewise Linear ◽  
Sampling Rate ◽  
Navier Stokes ◽  
Computational Domain ◽  
Cfd Simulations ◽  
High Sampling Rate ◽  
Interface Reconstruction ◽  
Image Velocimetry ◽  
Computational Fluid Dynamics Cfd

Abstract The kinematics under spilling and plunging breakers are investigated using both experimental and numerical methods. In a modular laboratory flume, the breakers were generated using dispersive focusing, and the kinematics underneath them were measured utilizing the Particle Image Velocimetry (PIV) technique. Using the state-of-art high-speed video cameras and lasers, the kinematics were measured at a high sampling rate without needing phase-locked averaging. Afterwards, Computational Fluid Dynamics (CFD) simulations were carried out for comparison purposes. These simulations were run in single-phase using a finite-volume based Navier-Stokes solver with a piecewise-linear interface reconstruction scheme. The spilling and plunging breakers from the measurements were reconstructed in the computational domain using an iterative scheme. As a result a good match with the measured waves was obtained in the simulations. Results indicate that even though measured kinematics are somewhat higher than the simulated ones especially in the spilling and overturning regions, the CFD simulations can accurately capture the relevant details of the flow and produce reasonably accurate kinematics in comparison with the PIV results.

scholarly journals Experimental investigations and analysis on churning losses of splash lubricated spiral bevel gears

2017 ◽  
Vol 18 (4) ◽  
pp. 412 ◽  
Author(s):  
S. Laruelle ◽  
C. Fossier ◽  
C. Changenet ◽  
F. Ville ◽  
S. Koechlin
Keyword(s):  
Experimental Tests ◽  
Operating Conditions ◽  
Experimental Investigations ◽  
Spiral Bevel Gear ◽  
Power Losses ◽  
Test Rig ◽  
Specific Test ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Spiral Bevel

Churning losses are a complex phenomenon which generates significant power losses when considering splash lubrication of gear units. However, only few works deal with bevel gears dipped lubrication losses. The objective of this study is to provide a wide variety of experimental tests on churning losses, especially getting interested in geometry of spiral bevel gears influence. A specific test rig was used in order to study a single spiral bevel gear partially immersed in an oil bath. Experiments have been conducted for several operating conditions in terms of speeds, lubricants, temperatures and gear geometries to study their impact on splash lubrication power losses. These experimental results are compared with the predictions from various literature sources. As the results did not agree well with the predictions for all operating conditions, an extended equation derived from previous works is introduced to estimate churning losses of bevel gears.

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