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

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.