CFD Analysis of Lubrication in Rotating Gears for Experimental Design and Software Validation

Lubrication plays a crucial role in enhancing the efficiency and durability of automotive gear systems by minimizing friction, wear, and heat generation. This study investigates gear lubrication using Computational Fluid Dynamics (CFD) simulations with Simerics MP+ software, focusing on validating its accuracy for various lubrication methods. The primary objective was to evaluate the performance of forced lubrication systems by examining key parameters such as mesh resolution, time step, oil jet position, and volumetric flow rate through a series of sensitivity analyses. To validate the simulation results, a comprehensive physical experiment was designed along with its components to replicate the simulated conditions. The experiment involves using high-speed cameras to capture oil distribution and behavior around rotating gears, and precision instrumentation to measure resistive torque. A direct comparison between the simulated and experimental results will help confirm the accuracy of the CFD model in predicting real-world lubrication behavior. Additionally, a secondary study on splash lubrication was conducted to assess its effectiveness relative to forced lubrication systems. The findings from this research highlight the importance of balancing cell size and time step to achieve accurate and efficient simulations. Furthermore, the study identified optimal jet positions and flow rates for the experimental setup to obtain measurable results. Although the final validation of Simerics MP+ is contingent upon completing the physical experiment, the initial findings indicate its potential as a reliable tool for analyzing gear lubrication systems. This study provides a framework for validating CFD models and sets a foundation for future research on advanced lubrication techniques. If the experimental results align with the simulations, Simerics MP+ can be confidently used in further studies, leading to improved design and performance of automotive and industrial gear systems. The broader implications of this research extend to developing more efficient and durable lubrication solutions for high-performance automotive and industrial applications.