ISSN   1004-0595

CN  62-1224/O4

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高速航空锥齿轮线速度对喷油润滑流场与温度场影响研究

Influence of the Impact of Velocity on Oil Injection Lubrication Flow Field and Temperature Field in High-Speed Aeronautical Bevel Gears

  • 摘要: 喷油润滑的航空弧齿锥齿轮由于高线速度常导致射流破碎和乏断油现象,并产生异常温升和变形,严重影响齿轮传动的寿命和服役性能. 针对高线速度对锥齿轮喷油特性影响规律不清的问题,建立了航空弧齿锥齿轮喷油润滑热-流耦合分析模型,研究了高达160 m/s线速度的航空弧齿锥齿轮流场和温度场特性. 发现线速度从40 m/s升高到160 m/s,齿面油液体积分数下降83.5%,润滑效果显著降低,且在120 m/s后齿面出现乏油状态,啮合区对流换热降低. 随转速升高齿轮风阻损失呈指数增长,在80 m/s后成为齿轮副的主要功率损失来源. 随线速度升高,齿轮不同部位温差不断增加,致使热应力和变形增大. 该研究为高速齿轮传动润滑和高承载设计提供支撑.

     

    Abstract: The gear transmission system in aircraft engines often operates under high-speed and heavy-load conditions. Reliable lubrication is crucial to ensure that the spiral bevel gears do not experience gear scuffing or pitting. In aircraft accessory gearboxes, spiral bevel gears often rely on oil jet lubrication. However, the oil spray parameters designed empirically do not consider the lubrication degradation caused by jet breakup due to rotational speed, making it difficult to meet the design requirements of aircraft gear transmission. A Finite Volume-based thermal-fluid coupling simulation model of spiral bevel gears has been established to consider the influence of actual conditions such as gear speed, oil spray velocity, spray angle on lubrication and heat dissipation effects, supporting the high-reliability and high-power density design of aircraft gear transmission. The model investigated the flow field and temperature field where the velocity of the gear reached up to 160 m/s. It comprised modules for analyzing the lubrication flow field of gear oil spray and calculating the temperature field of the gear. The Dynamic Mesh method with Global Remeshing approach was used to simulate the rotation of gears in the flow field, and the RNG k-\varepsilon model with higher accuracy was employed to analyze turbulence for high rotational flow. The standard wall functions were used to analyze the distribution of oil on the gear surface. Stability checks and mesh independence checks were conducted to confirm the reliability of the results. The flow field analysis module provided parameters such as the gear tooth surface oil volume fraction, wall heat transfer coefficient, and windage loss. The comprehensive viscosity was employed to correlate gear lubrication with gear oil-air ratio, combined with meshing loss of spiral bevel gears under oil jet conditions to compute frictional heat flow at different linear velocities. Considering multiple heat sources such as heating from windage and meshing heat generation, and multiple heat dissipation channels including convective heat transfer and thermal conduction, the temperature distribution of the gear was determined. By comparing the differences in aerodynamic drag loss calculations between NASA experiments, empirical formulas, and the model, the accuracy of the model was validated. The model analysis revealed that as the gear velocity increased from 40 m/s to 160 m/s, the jet breakup offset phenomenon intensified, leading to an 83.5% decrease in the average oil-air ratio on the gear surface. The lubricating oil significantly affected convective heat transfer on the gear surface, with a sharp increase in the wall heat transfer coefficient at the gear oil jet location. As the velocity increased, the rising trend of convective wall transfer coefficient in the meshing zone shifted to a decreasing trend after 120 m/s, indicating deteriorating lubrication heat transfer conditions. With the increase in velocity, windage loss exhibited a nearly exponential growth pattern. The windage loss accounts for over 80% of the total loss at 160 m/s, becoming the primary source of loss at high gear speeds and resulting in reduced transmission efficiency.

     

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