| Citation: | WEN Wuyi, WANG Qiao, LIU Huaiju, et al. Thermal-fluid coupling analysis of a transmission system of accessory gearbox of an aero-engine under multi-branch lubrication state[J]. Journal of Aerospace Power, 2025, 40（10）：20240451 doi: 10.13224/j.cnki.jasp.20240451
|
Given the lack of analysis methods for thermal-fluid coupling in high-speed gear transmission systems with complex oil multi-branch lubrication, a thermal-fluid analysis model based on the multiphase flow finite volume method was proposed. The flow field and temperature field within the gearbox were studied with this model. Bending and abrupt contraction of the oil route caused significant pressure drops. This affected the jet velocity and oil-air ratio at the outlet, leading to fragmentation of high-speed gear meshing jets and lower lubrication and cooling performance. It was found that the initial structure of the gearbox suffered from jet fragmentation and oil storage issues, resulting in a windage loss of 12.30 kW, which was 85.20% of the total loss. Improvements to the oil system increased the jet velocity and oil-air ratio. By adding oil outlets and installing shrouding, the system’s windage loss was significantly reduced to 5.22 kW, increasing the transmission efficiency from 93.54% to 96.67%. It provids methodological support for the high-power-density design of high-speed aviation transmission.
| [1] |
LU Zehua, CHEN Yiming, LIU Huaiju, et al. A high-power-density design method for polymer gear systems via an adaptive non-dominated sorting genetic algorithm Ⅲ and surrogate sub-models[J]. Materials & Design, 2024, 240: 112875.
|
| [2] |
CHEN Taimin, ZHU Caichao, LIU Huaiju, et al. Simulation and experiment of carburized gear scuffing under oil jet lubrication[J]. Engineering Failure Analysis, 2022, 139: 106406. doi: 10.1016/j.engfailanal.2022.106406
|
| [3] |
林基恕, 张振波. 21世纪航空发动机动力传输系统的展望[J]. 航空动力学报, 2001, 16(2): 108-114, 118. LIN Jishu, ZHANG Zhenbo. Prospects of aeroengine power transmission system in the 21st century[J]. Journal of Aerospace Power, 2001, 16(2): 108-114, 118. (in Chinese
LIN Jishu, ZHANG Zhenbo. Prospects of aeroengine power transmission system in the 21st century[J]. Journal of Aerospace Power, 2001, 16(2): 108-114, 118. (in Chinese)
|
| [4] |
MARJADI D, PARK Y, GASEVSKI D, et al. Simulation driven design workflow for aircraft gearbox[R]. AIAA 2020-2648, 2020.
|
| [5] |
林腾蛟, 黄河, 彭建涛, 等. 混合润滑条件下的星形人字齿轮系统温度场[J]. 航空动力学报, 2020, 35(5): 1066-1080. LIN Tengjiao, HUANG He, PENG Jiantao, et al. Temperature field of double helical star gear transmission system in mixed lubrication condition[J]. Journal of Aerospace Power, 2020, 35(5): 1066-1080. (in Chinese
LIN Tengjiao, HUANG He, PENG Jiantao, et al. Temperature field of double helical star gear transmission system in mixed lubrication condition[J]. Journal of Aerospace Power, 2020, 35(5): 1066-1080. (in Chinese)
|
| [6] |
SAEGUSA D, KAWAI S. CFD analysis of lubricant fluid flow in automotive transmission[C]//SAE Technical Paper Series. 400 Commonwealth Drive. Warrendale, PA, US: SAE International, 2014: 1772-1780.
|
| [7] |
MACCIONI L, CONCLI F. Computational fluid dynamics applied to lubricated mechanical components: review of the approaches to simulate gears, bearings, and pumps[J]. Applied Sciences, 2020, 10(24): 8810. doi: 10.3390/app10248810
|
| [8] |
LIU H, LINK F, LOHNER T, et al. Computational fluid dynamics simulation of geared transmissions with injection lubrication[J]. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 2019, 233(21/22): 7412-7422.
|
| [9] |
WANG Yanzhong, SONG Guanhua, NIU Wentao, et al. Influence of oil injection methods on the lubrication process of high speed spur gears[J]. Tribology International, 2018, 121: 180-189. doi: 10.1016/j.triboint.2018.01.062
|
| [10] |
JIANG Xinghe, ZHOU Changjiang, SU Jie, et al. Injection parameter design to improve the high-speed gear heat dissipation: CFD simulation and regression orthogonal experiment[J]. Simulation Modelling Practice and Theory, 2023, 128: 102795. doi: 10.1016/j.simpat.2023.102795
|
| [11] |
YANG Duan, LIU He, ZHONG Jianfeng, et al. Influence of nozzle layouts on the heat-flow coupled characteristics for oil-jet lubricated spur gears[J]. Lubricants, 2023, 11(1): 25. doi: 10.3390/lubricants11010025
|
| [12] |
DESHPANDE S, JOSHI H, MADHAVAN J, et al. Two-way coupled CFD approach for predicting gear temperature of OilJet lubricated transmissions[J]. SAE International Journal of Commercial Vehicles, 2018, 11(3): 163-170. doi: 10.4271/02-11-03-0013
|
| [13] |
LU Fengxia, WANG Meng, PAN Wenbin, et al. CFD-based investigation of lubrication and temperature characteristics of an intermediate gearbox with splash lubrication[J]. Applied Sciences, 2020, 11(1): 352-372. doi: 10.3390/app11010352
|
| [14] |
YAZDANI M, SOTERIOU M C, SUN Fanping, et al. Prediction of the thermo-fluids of gearbox systems[J]. International Journal of Heat and Mass Transfer, 2015, 81: 337-346. doi: 10.1016/j.ijheatmasstransfer.2014.10.038
|
| [15] |
YAZDANI M, SOTERIOU M C. A novel approach for modeling the multiscale thermo-fluids of geared systems[J]. International Journal of Heat and Mass Transfer, 2014, 72: 517-530. doi: 10.1016/j.ijheatmasstransfer.2014.01.035
|
| [16] |
YAZDANI M, SOTERIOU M, BOTROS B, et al. A novel approach to model thermo-fluids of gearbox systems[R]. ASME Paper HT2013-17404, 2013.
|
| [17] |
LU Yaguo, LIU Zhenxia, HUANG Shengqin, et al. Numerical simulation of aero-engine lubrication system[J]. Journal of Engineering for Gas Turbines and Power, 2009, 131(3): 034503. doi: 10.1115/1.3026573
|
| [18] |
DE VIZIO A, SENATORE A, BUONO D, et al. A simulated analysis of the lubrication circuit of an in-line twin automotive engine[R]. SAE Technical Paper 2014-01-1081, 2014.
|
| [19] |
MAHENDIRAN P, BALASUBRAMANIAN B, MANAVALAN M, et al. A design environment for performance modeling and analysis of aero engine lubrication systems[R]. ASME Paper GTINDIA 2013-3542, 2013.
|
| [20] |
DHAR S, AFJEH H, SRINIVASAN C, et al. Transient, three dimensional CFD model of the complete engine lubrication system[J]. SAE International Journal of Engines, 2016, 9(3): 1854-1862. doi: 10.4271/2016-01-1091
|
| [21] |
POLASTRI M, STORCHI G, BATTARRA M, et al. A lumped parameter approach for the filling analysis of V6 engine lubrication systems[J]. Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering, 2022, 236(1): 29-39. doi: 10.1177/09544070211018877
|
| [22] |
CONCLI F, GORLA C. Windage, churning and pocketing power losses of gears: different modeling approaches for different goals[J]. Forschung Im Ingenieurwesen, 2016, 80(3): 85-99.
|
| [23] |
WINFREE D D. Reducing gear windage losses from high speed gears[C]// International Design Engineering Technical Conferences and Computers and Information in Engineering Conference. Baltimore, Maryland, US: ASME, 2000: 747-756.
|
| [24] |
ARISAWA H, NISHIMURA M, IMAI H, et al. CFD simulation for reduction of oil churning loss and windage loss on aeroengine transmission gears[R]. ASME Paper GT2009-59226, 2009.
|
| [25] |
ARISAWA H, TANAKA M, HASHIMOTO H, et al. Applicability of numerical simulation to the classification of fluid dynamic loss in aeroengine transmission gears[R]. ASME Paper GTP-23-1493, 2023.
|
| [26] |
TURNER A, MORVAN H P, SIMMONS K. Two phase CFD modelling of a spiral bevel gear using particle injections and a wall film model[R]. ASME Paper GT2013-94735, 2013.
|
| [27] |
TURNER A, MORVAN H P, SIMMONS K. Two phase computational study of flow behaviour in a region within an aeroengine gearbox[R]. ASME Paper GT2014-26128, 2014.
|
| [28] |
HASHIMOTO H, ARISAWA H, KONDO K, et al. Computational fluid dynamics in a fan-drive gear system of an aeroengine[R]. ASME Paper : GT2023-101589, 2023.
|
| [29] |
文武翊, 林勤杰, 王中荣, 等. 高速航空锥齿轮线速度对喷油润滑流场与温度场影响研究[J]. 摩擦学学报, 2025, 45(4): 525-536. WEN Wuyi, LIN Qinjie, WANG Zhongrong, et al. Influence of the impact of velocity on oil injection lubrication flow field and temperature field in high-speed aeronautical bevel gear[J]. Tribology, 2025, 45(4): 525-536. (in Chinese
WEN Wuyi, LIN Qinjie, WANG Zhongrong, et al. Influence of the impact of velocity on oil injection lubrication flow field and temperature field in high-speed aeronautical bevel gear[J]. Tribology, 2025, 45(4): 525-536. (in Chinese)
|
| [30] |
陈炳瑞, 朱才朝, 林勤杰, 等. FZG齿轮箱热流耦合分析与验证方法研究[J]. 摩擦学学报, 2025, 45(6): 797-811. CHEN Bingrui, ZHU Caichao, LIN Qinjie, et al. FZG gearbox thermal fluid coupling analysis and verification methodology research [J/OL]. Tribology, 2025, 45(6): 797-811. (in Chinese
CHEN Bingrui, ZHU Caichao, LIN Qinjie, et al. FZG gearbox thermal fluid coupling analysis and verification methodology research [J/OL]. Tribology, 2025, 45(6): 797-811. (in Chinese)
|
| [31] |
CHEN Taimin, ZHU Caichao, CHEN Jinxiao, et al. A review on gear scuffing studies: theories, experiments and design[J]. Tribology International, 2024, 196: 109741. doi: 10.1016/j.triboint.2024.109741
|
| [32] |
吴超琦, 罗健, 周莹, 等. 中央传动齿轮箱复杂油路性能仿真[J]. 浙江大学学报(工学版), 2023, 57(11): 2337-2344. WU Chaoqi, LUO Jian, ZHOU Ying, et al. Performance simulation of complex oil circuit of inlet gearbox[J]. Journal of Zhejiang University (Engineering Science), 2023, 57(11): 2337-2344. (in Chinese doi: 10.3785/j.issn.1008-973X.2023.11.021
WU Chaoqi, LUO Jian, ZHOU Ying, et al. Performance simulation of complex oil circuit of inlet gearbox[J]. Journal of Zhejiang University (Engineering Science), 2023, 57(11): 2337-2344. (in Chinese) doi: 10.3785/j.issn.1008-973X.2023.11.021
|
| [33] |
MARTIN K F. A review of friction predictions in gear teeth[J]. Wear, 1978, 49(2): 201-238. doi: 10.1016/0043-1648(78)90088-1
|
| [34] |
ECHÁVARRI OTERO J, DE LA GUERRA OCHOA E, CHACÓN TANARRO E, et al. Friction coefficient in mixed lubrication: a simplified analytical approach for highly loaded non-conformal contacts[J]. Advances in Mechanical Engineering, 2017, 9(7): 168781401770626.
|
| [35] |
FONDELLI T, ANDREINI A, DA SOGHE R, et al. Numerical simulation of oil jet lubrication for high speed gears[J]. International Journal of Aerospace Engineering, 2015, 2015: 752457.
|
| [36] |
CENTER N G R, DELGADO I, HURRELL M. Experimental investigation of shrouding on meshed spur gear windage power loss[R]. NASA/TM-2017-219526, 2017.
|
DownLoad:
