Gearbox housing geometry and oil guide plates strongly influence gearbox oil flow and interaction of oil with machine elements. Guided oil flow can increase gearbox efficiency and improve heat management. Recent research studies have demonstrated the potential of Computational Fluid Dynamics (CFD) simulations to predict the gearbox oil flow and no-load losses. Thereby, the influence of housing geometry and guide plates has rarely been addressed. This study focuses on a CFD analysis on the oil flow of a dip lubricated spur gear stage with a guide plate. Grid-based CFD models with different simulation setups were confronted and evaluated. Results show that the selection of the simulation setup with respect to the acceleration ramp and mesh size needs to address the considered object of investigation and the desired depth of information. An appropriate simulation setup shows great accordance with recordings of the oil distribution by a high-speed camera. A detailed analysis of the simulation results identified the contribution of different gear surface zones to the no-load gear loss torque. For the considered guide plate a strong interaction of oil flow and loss torque due to pressure forces on the tooth flank surface zones and due to shear forces on the front and tip circle surface zones of the gears was determined.

Lubricating greases are widely used in e.g. open gear drives and gearboxes with difficult sealing conditions. The efficiency and heat balance of grease-lubricated gearboxes depend strongly on the lubrication mechanisms channeling and circulating, for which the grease flow is causal. The computational fluid dynamics opens up the possibility to visualize and understand the grease flow in gearboxes in more detail. In this study, a single-stage gearbox lubricated with an NLGI 1-2 grease was modeled by the finite-volume method to numerically investigate the fluid flow. Results show that the rotating gears influence the grease sump only locally around the gears. For a low grease fill volume, the rotation of the gears is widely separated from the grease sump. For a high grease fill volume, a pronounced gear-grease interaction results in a circulating grease flow around the gears. The simulated grease distributions show good accordance with high-speed camera recordings.

Power losses in gearboxes result in frictional heating. Sufficient heat transfer from the gearbox to the environment is required for reliable operation. The heat dissipation from gears is linked to their interaction with fluids in the gearbox. Recent research has demonstrated the use of Computational Fluid Dynamics (CFD) to predict the gearbox fluid flow and no-load losses in an isothermal manner. This study focuses on a numerical analysis of the heat dissipation within a dry-lubricated gearbox under atmospheric conditions. Spur gears and helical gears are investigated. The air flow in the gearbox as well as the heat dissipation over the gear surfaces are evaluated in detail. The results show that the gear geometry and the circumferential speed have a strong impact on the air flow. Especially, the axial inflow of air to the gears has a great influence on the heat dissipation. Conveying effects of helical gears lead to a multidirectional airflow, resulting in higher values of the heat transfer coefficient on the gear surface compared to spur gears.

Gearbox lubrication plays a decisive role in both load capacity and efficiency. It is necessary for the formation of a lubricant film in tribological contacts, and for heat dissipation. Grease lubrication is often applied to gearboxes at a low operating speed and means that, for example, less effort is required in sealing design compared to oil lubrication. Over the years, the computational fluid dynamics (CFD) method has frequently been applied to support the lubrication-related design of gearboxes. However, very few studies have focused on grease lubrication. Whereas oil can generally be considered as Newtonian fluid, grease displays complex non-Newtonian flow behavior. In this study, the grease lubrication of a single-stage test gearbox is investigated by means of a finite-volume based CFD model. The numerical results on the grease flow show good accordance with high-speed camera recordings, and clearly display the lubrication mechanisms of “channeling” and “circulating”. These first results on grease flow simulation in gearboxes offer a starting point for further numerical studies.