Gear box

Gear Box

Description:

Gear box is the most important component in every vechicles.It protects the gear and provides lubrication for the gears.Here,we are going to analyse the lubrication and flow pattern in the gear box by using various lubricant and various clearance angle.

Case 1: Analysis of Gear sloshing effect

• Normal clearance
• lubricant density=998.1kg/m^3
• viscosity=0.001003 kg/m-s

Case 2: Analysis of Gear sloshing effect

• Normal clearance
• Lubricant density=871kg/m^3
• viscosity=0.04006889 kg/m-s

Case 3: Analysis of Gear sloshing effect

• Increased clearance
• lubricant density=998.1kg/m^3
• viscosity=0.001003 kg/m-s

Case 4: Analysis of Gear sloshing effect

• Increased clearance
• Lubricant density=871kg/m^3
• viscosity=0.04006889 kg/m-s

Steps in Analysis of Gear Sloshing effect:

• Geometry
• Meshing
• Set up
• Solution
• Result

Case 1 : Analysis of Gear Sloshing effect

• Normal clearance
• lubricant density=998.2kg/m^3
• viscosity=0.001003 kg/m-s

Geometry:

• Importing the 3D model
• Volume extraction
• Extracting the 2D model

1.Importing the 3D model:

The first step is to import the 3D model to the space claim.

File > Open > Model (Select) > Import.

2.Volume extraction:

Fluid volume extraction is defined as extracting the volume of the fluid region.In this case,we are extracting the volume of the fluid region.Here,the space occuied by the gear and lubricant is the fluid medium.

3.Extracting the 2D model:

The next step is to extract the 2D model from the 3D geometry.The 2D model is extracted by creating the planes along the three axis and splitting the body of the 3D model by suing the split body tool.After that the splitted body is copied and pasted into the another geometry.

Meshing:

Meshing is the process of dividing the solid model into a small individual element.Here we are discretizing the 2D model into a small element of size 0.003m.We obtained,

• No of elements =16399.
• No of nodes =9655

After completion of meshing,naming should be done.

Set up:

In set up,the first step is to load the required file for the motion of the gears.The other conditions is as follows,

General :1.Pressure based solver

2.Transient state condition

Model :1.Multiphase-Volume of Fluid.

2.Viscous-K epsilon-Realizable-Enhanced wall function.

Material :1.Fluid- Water & oil (density-998.2kg/m^3,viscosity-0.001003 kg/m-s).

Cell zone condition :1.Volume-fluid

Dynamic mesh : Create dynamic mesh.

Initialization :1.Standard initialization

2.Patch

Solution:

It is a post processing stage.Here,the sloshing effect of the gear is analysed.After that the calculation is set for,

• Number of time steps=1600
• Time step size= 0.0001s.

Result:

Animation:

Case 2: Analysis of Gear Sloshing effect

• Normal clearancekg/m^3
• lubricant density=871kg/m^3
• viscosity=0.04006889 kg/m-s

Geometry:

• Importing the 3D model
• Extracting the 2D model

1.Importing the 3D model:

The first step is to import the 3D model to the space claim.

File > Open > Model (Select) > Import.

2.Volume extraction:

Fluid volume extraction is defined as extracting the volume of the fluid region.In this case,we are extracting the volume of the fluid region.Here,the space occuied by the gear and lubricant is the fluid medium.

3.Extracting the 2D model:

The next step is to extract the 2D model from the 3D geometry.The 2D model is extracted by creating the planes along the three axis and splitting the body of the 3D model by suing the split body tool.After that the splitted body is copied and pasted into the another geometry.

Meshing:

Meshing is the process of dividing the solid model into a small individual element.Here we are discretizing the 2D model into a small element of size 0.003m.We obtained,

• No of elements =16054.
• No of nodes =9444.

After completion of meshing,naming should be done.

Set up:

In set up,the first step is to load the required file for the motion of the gears.The other conditions is as follows,

General :1.Pressure based solver

2.Transient state condition

Model :1.Multiphase-Volume of Fluid.

2.Viscous-K epsilon-Realizable-Enhanced wall function.

Material :1.Fluid- Water & oil (density-871kg/m^3,viscosity=0.04006889 kg/m-s)

Cell zone condition :1.Volume-fluid

Dynamic mesh : Create dynamic mesh.

Initialization :1.Standard initialization

2.Patch

Solution:

It is a post processing stage.Here,the sloshing effect of the gear is analysed.After that the calculation is set for,

• Number of time steps=720.
• Time step size= 0.0001s.

Result:

Animation:

Case 3: Analysis of Gear sloshing effect

• Increased clearance
• lubricant density=998.1kg/m^3
• viscosity=0.001003 kg/m-s

Geometry:

• Importing the 3D model
• Extracting the 2D model

1.Importing the 3D model:

The first step is to import the 3D model to the space claim.

File > Open > Model (Select) > Import.

2.Volume extraction:

Fluid volume extraction is defined as extracting the volume of the fluid region.In this case,we are extracting the volume of the fluid region.Here,the space occuied by the gear and lubricant is the fluid medium.

3.Extracting the 2D model:

The next step is to extract the 2D model from the 3D geometry.The 2D model is extracted by creating the planes along the three axis and splitting the body of the 3D model by suing the split body tool.After that the splitted body is copied and pasted into the another geometry.

Meshing:

Meshing is the process of dividing the solid model into a small individual element.Here we are discretizing the 2D model into a small element of size 0.003m.We obtained,

• No of elements =16399.
• No of nodes =9655.

After completion of meshing,naming should be done.

Set up:

In set up,the first step is to load the required file for the motion of the gears.The other conditions is as follows,

General :1.Pressure based solver

2.Transient state condition

Model :1.Multiphase-Volume of Fluid.

2.Viscous-K epsilon-Realizable-Enhanced wall function.

Material :1.Fluid- Water & oil (density-998.1kg/m^3,viscosity-0.001003kg/m-s).

Cell zone condition :1.Volume-fluid

Dynamic mesh : Create dynamic mesh.

Initialization :1.Standard initialization

2.Patch

Solution:

It is a post processing stage.Here,the sloshing effect of the gear is analysed.After that the calculation is set for,

• Number of time steps=733
• Time step size= 0.0001s.

Result:

Case 4: Analysis of Gear sloshing effect

• Increased clearance
• Lubricant density=871kg/m^3
• viscosity=0.04006889 kg/m-s

Geometry:

• Importing the 3D model
• Extracting the 2D model

1.Importing the 3D model:

The first step is to import the 3D model to the space claim.

File > Open > Model (Select) > Import.

3.Volume extraction:

Fluid volume extraction is defined as extracting the volume of the fluid region.In this case,we are extracting the volume of the fluid region.Here,the space occuied by the gear and lubricant is the fluid medium.

3.Extracting the 2D model:

The next step is to extract the 2D model from the 3D geometry.The 2D model is extracted by creating the planes along the three axis and splitting the body of the 3D model by suing the split body tool.After that the splitted body is copied and pasted into the another geometry.

Meshing:

Meshing is the process of dividing the solid model into a small individual element.Here we are discretizing the 2D model into a small element of size 0.003m.We obtained,

• No of elements =16256.
• No of nodes =9584.

After completion of meshing,naming should be done.

Set up:

In set up,the first step is to load the required file for the motion of the gears.The other conditions is as follows,

General :1.Pressure based solver

2.Transient state condition

Model :1.Multiphase-Volume of Fluid.

2.Viscous-K epsilon-Realizable-Enhanced wall function.

Material :1.Fluid- Water & oil (density-871kg/m^3,viscosity-0.04006889kg/m-s).

Cell zone condition :1.Volume-fluid

Dynamic mesh : Create dynamic mesh.

Initialization :1.Standard initialization

2.Patch

Solution:

It is a post processing stage.Here,the sloshing effect of the gear is analysed.After that the calculation is set for,

• Number of time steps=660
• Time step size= 0.0001s.

Result:

Conclusion:

In case 1,the gear teeths are coarse and the density of the lubricant is high.In case 2,the gear teeths are coarse and the lubricant density is low when compared to case 1.Whereas, in case 3 and case 4 the clearance is high.In case 3,the fluid density is high and in case 4 it is low.While comparing all the four cases the flow is very smooth in the case 4.Therefore,the conclusion is case 4 is better than all the 3 cases.