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Simulation of gear sloshing effect for four different cases using ANSYS FLUENT

AAbubakar Khan24 Feb 2020

Objective

Simulate the fluid flow for the given system of gear for the following cases:

  • Gearbox sloshing effect with water as lubricant(High clearance)
  • Gearbox sloshing effect with Oil as lubricant(High clearance)
  • Gearbox sloshing effect with water as lubricant(Low clearance)
  • Gearbox sloshing effect with Oil as lubricant(Low clearance)

Case1:Gearbox sloshing effect with water as lubricant(High clearance)

Step1.Geometry

  • Above image shows 3d gear which we need to simulate,but since we have a cell limitation so,for that we will convert above 3D gear into 2D plane in the following steps

Volume Extraction

Splitting the body along XY plane

  • Above image shows the required 2D plane which we need to simulate

Step2.Meshing

  • Before doing meshing we need to assign name selection which we can in below image

  • Mesh method:Triangular
  • Element size=1e-3m
  • Capture Proximity:On

Mesh Details

Step3.Setup

  • Analysis:Transient
  • Type:Pressure Based
  • Gravity:Y=-9.81m/s^2
  • Turbulence model:K-epsilon,Realizable with enhanced wall treatment

Multiphase

  • Method:Volume of fluid
  • Number of Eulerain phase:2
  • Formulation:Implicit

Materials

Air

  • Density:1.225 kg/m^3
  • Viscosity:0.000017894 kg/m^3

Water

  • Density:998.2 kg/m^3
  • Viscosity:0.00100 kg/m-s

Phases

  • Primary phase:Air
  • Secondary phase:Water

User defined function

  • For the gear rotation we need to build UDF file and load into Fluent
  • UDF file name:rate.c
  • Code of UDF file
#include \"udf.h\"

DEFINE_CG_MOTION(right_motion, dt, vel, omega, time, dtime)
{
	vel[0] = 0.0;
	vel[1] = 0.0;
	vel[2] = 0.0;

	omega[0] = 0.0;
	omega[1] = 0.0;
	omega[2] = 2.0e2; /* [rad/s]*/
}
DEFINE_CG_MOTION(left_motion, dt, vel, omega, time, dtime)
{
	vel[0] = 0.0;
	vel[1] = 0.0;
	vel[2] = 0.0;

	omega[0] = 0.0;
	omega[1] = 0.0;
	omega[2] = -2.0e2; /* [rad/s]*/
}

Dynamic mesh

  • Methods:Smoothing & Remeshing
  • Zone name:left gear
  • Type:Rigid body
  • Center of Gravity:(-65,0,0)mm
  • Zone name:Right gear
  • Type:Rigid body
  • Center of Gravity:(67.5,0,0)mm

Remeshing Details

Region of Mark

  • Name:Water surface
  • Type:Quad
  • Location:Inside
  • Diagonal Start Point:(-0.14,-0.09241,0)m
  • End Point:(0.14,-0.02,0)

Region of Mark details

Time step and time step size

  • Time step size:1e-4
  • Number of time steps:700

Initilization

  • Now,we need to initialize by using hybrid scheme
  • After initilization we need to patch
  • Phase:Water
  • Volume fraction
  • Value:1

Step4.Results

Residuals

Volume fraction of water

Volume fraction of water animation

Case2:Gearbox sloshing effect with Oil as lubricant(High clearance)

Upto Step 2 this case is similar to case 1

Step3.Setup

  • Analysis:Transient
  • Type:Pressure Based
  • Gravity:Y=-9.81m/s^2
  • Turbulence model:K-epsilon,Realizable with enhanced wall treatment

Multiphase

  • Method:Volume of fluid
  • Number of Eulerain phase:2
  • Formulation:Implicit

Materials

Air

  • Density:1.225 kg/m^3
  • Viscosity:0.000017894 kg/m^3

Oil

  • Density:871 kg/m^3
  • Viscosity:0.04006889 kg/m-s

Phases

  • Primary phase:Air
  • Secondary phase:Oil

User defined function

  • For the gear rotation we need to build UDF file and load into Fluent
  • UDF file name:rate.c
  • Code of UDF file
#include \"udf.h\"

DEFINE_CG_MOTION(right_motion, dt, vel, omega, time, dtime)
{
	vel[0] = 0.0;
	vel[1] = 0.0;
	vel[2] = 0.0;

	omega[0] = 0.0;
	omega[1] = 0.0;
	omega[2] = 2.0e2; /* [rad/s]*/
}
DEFINE_CG_MOTION(left_motion, dt, vel, omega, time, dtime)
{
	vel[0] = 0.0;
	vel[1] = 0.0;
	vel[2] = 0.0;

	omega[0] = 0.0;
	omega[1] = 0.0;
	omega[2] = -2.0e2; /* [rad/s]*/
}

Dynamic mesh

  • Methods:Smoothing & Remeshing
  • Zone name:left gear
  • Type:Rigid body
  • Center of Gravity:(-65,0,0)mm
  • Zone name:Right gear
  • Type:Rigid body
  • Center of Gravity:(67.5,0,0)mm

Remeshing Details

Region of Mark

  • Name:Oil surface
  • Type:Quad
  • Location:Inside
  • Diagonal Start Point:(-0.14,-0.09241,0)m
  • End Point:(0.14,-0.02,0)

Region of Mark details

Time step and time step size

  • Time step size:1e-4
  • Number of time steps:700

Initilization

  • Now,we need to initialize by using hybrid scheme
  • After initilization we need to patch
  • Phase:Oil
  • Volume fraction
  • Value:1

Step4.Results

Residuals

Volume fraction of Oil

Volume fraction of Oil animation

Case3:Gearbox sloshing effect with water as lubricant(Low clearance)

Step1.Geometry

  • Above image shows 3d gear which we need to simulate,but since we have a cell limitation so,for that we will convert above 3D gear into 2D plane in the following steps

Volume Extraction

Splitting the body along XY plane

  • Above image shows the required 2D plane which we need to simulate

Step2.Meshing

  • Before doing meshing we need to assign name selection which we can in below image

  • Mesh method:Triangular
  • Element size=1e-3m
  • Capture Proximity:On

Mesh Details

Step3.Setup

  • Analysis:Transient
  • Type:Pressure Based
  • Gravity:Y=-9.81m/s^2
  • Turbulence model:K-epsilon,Realizable with enhanced wall treatment

Multiphase

  • Method:Volume of fluid
  • Number of Eulerain phase:2
  • Formulation:Implicit

Materials

Air

  • Density:1.225 kg/m^3
  • Viscosity:0.000017894 kg/m^3

Water

  • Density:998.2 kg/m^3
  • Viscosity:0.00100 kg/m-s

Phases

  • Primary phase:Air
  • Secondary phase:Water

User defined function

  • For the gear rotation we need to build UDF file and load into Fluent
  • UDF file name:rate.c
  • Code of UDF file
#include \"udf.h\"

DEFINE_CG_MOTION(right_motion, dt, vel, omega, time, dtime)
{
	vel[0] = 0.0;
	vel[1] = 0.0;
	vel[2] = 0.0;

	omega[0] = 0.0;
	omega[1] = 0.0;
	omega[2] = 2.0e2; /* [rad/s]*/
}
DEFINE_CG_MOTION(left_motion, dt, vel, omega, time, dtime)
{
	vel[0] = 0.0;
	vel[1] = 0.0;
	vel[2] = 0.0;

	omega[0] = 0.0;
	omega[1] = 0.0;
	omega[2] = -2.0e2; /* [rad/s]*/
}

Dynamic mesh

  • Methods:Smoothing & Remeshing
  • Zone name:left gear
  • Type:Rigid body
  • Center of Gravity:(0,0,0)mm
  • Zone name:Right gear
  • Type:Rigid body
  • Center of Gravity:(115,0,0)mm

Remeshing Details

Region of Mark

  • Name:Water surface
  • Type:Quad
  • Location:Inside
  • Diagonal Start Point:(-0.2,-0.09,0)m
  • End Point:(0.2,-0.015,0)

Region of Mark details

Time step and time step size

  • Time step size:1e-4
  • Number of time steps:700

Initilization

  • Now,we need to initialize by using hybrid scheme
  • After initilization we need to patch
  • Phase:Water
  • Volume fraction
  • Value:1

Step4.Results

Residuals

Volume fraction of water

Volume fraction of water animation

Case4:Gearbox sloshing effect with Oil as lubricant(Low clearance)

Upto Step 2 this case is similar to case 3

Step3.Setup

  • Analysis:Transient
  • Type:Pressure Based
  • Gravity:Y=-9.81m/s^2
  • Turbulence model:K-epsilon,Realizable with enhanced wall treatment

Multiphase

  • Method:Volume of fluid
  • Number of Eulerain phase:2
  • Formulation:Implicit

Materials

Air

  • Density:1.225 kg/m^3
  • Viscosity:0.000017894 kg/m^3

Oil

  • Density:871 kg/m^3
  • Viscosity:0.04006889 kg/m-s

Phases

  • Primary phase:Air
  • Secondary phase:Oil

User defined function

  • For the gear rotation we need to build UDF file and load into Fluent
  • UDF file name:rate.c
  • Code of UDF file
#include \"udf.h\"

DEFINE_CG_MOTION(right_motion, dt, vel, omega, time, dtime)
{
	vel[0] = 0.0;
	vel[1] = 0.0;
	vel[2] = 0.0;

	omega[0] = 0.0;
	omega[1] = 0.0;
	omega[2] = 2.0e2; /* [rad/s]*/
}
DEFINE_CG_MOTION(left_motion, dt, vel, omega, time, dtime)
{
	vel[0] = 0.0;
	vel[1] = 0.0;
	vel[2] = 0.0;

	omega[0] = 0.0;
	omega[1] = 0.0;
	omega[2] = -2.0e2; /* [rad/s]*/
}

Dynamic mesh

  • Methods:Smoothing & Remeshing
  • Zone name:left gear
  • Type:Rigid body
  • Center of Gravity:(0,0,0)mm
  • Zone name:Right gear
  • Type:Rigid body
  • Center of Gravity:(115,0,0)mm

Remeshing Details

Region of Mark

  • Name:Oil surface
  • Type:Quad
  • Location:Inside
  • Diagonal Start Point:(-0.2,-0.09,0)m
  • End Point:(0.2,-0.015,0)

Region of Mark details

Time step and time step size

  • Time step size:1e-4
  • Number of time steps:700

Initilization

  • Now,we need to initialize by using hybrid scheme
  • After initilization we need to patch
  • Phase:Oil
  • Volume fraction
  • Value:1

Step4.Results

Residuals

Volume fraction of Oil

Volume fraction of Oil animation

Conclusion

  • Simulation of Gear sloshing effect for four different cases is successfully performed
  • In case 1 & 2,we have use gear with high clearance.The high clearance causes faster lubrication of gear teeth.
  • In case 3 & 4,we have use gear with low clearance.The low clearance takes longer time for the lubrication to stick on the surface of the gear teeth.
  • The oil has high viscosity as compare to water & hence it sticks to the surface of the gear teeth better & for alonger time.
  • The water has low dynamic viscosity hence it produce turbulence & splashing more has compare to water
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