Efficiency improvement is the new challenge in all fields of design. In this scenario the reduction of power losses is becoming more and more a main concern also in the design of power transmissions. Appropriate models to predict power losses are therefore required from the earliest stages of the design phase. The aim of this project is to carry out lubrication simulations of several variants of a cylindrical roller bearing to understand the lubricant distribution and the related churning power losses. Several strategies to reduce the computational effort were used. Among them the sectorial symmetry and three innovative meshing strategies (purely analytical with and without interfaces and analytical/subtractive) that were implemented in the OpenFOAM ® environment. The results of the different approaches were compared among them and reasonable savings in terms of computational effort were shown.

Efficiency improvement is the new challenge in all fields of design. In this scenario the reduction of power losses is becoming more and more a main concern also in the design of power transmissions. Appropriate models to predict power losses are therefore from the earliest stages of the design phase. The aim of the project is to carry on lubrication simulations of several variants of a cylindrical-roller-bearing to understand the lubricant distribution and the related churning power losses. Several strategies to reduce the computational effort have been used. Among them the sectorial symmetry and three innovative meshing strategies (purely analytical with and without interfaces and analytical/subtractive) that have been implemented in the OpenFOAM® environment. The results of the different approaches were compared among them and with experimental observations showing good agreement and reasonable savings in terms of computational effort.