Prediction and optimization of lubrication performance for a transfer case based on computational fluid dynamics

Abstract

The lubrication performance and lubricant volume are of great significance in the design and operating processes for closed mechanical assemblies. A transfer case was taken as the research object, and simulations of flow fields under different working scenarios based on computational fluid dynamics and optimization of lubricant volume were performed. First, a model was proposed based on the volume of fluid method, and the model was validated when good agreement was achieved between simulation and experimental results. Next, the lubrication performances under different lubricant volumes and gear rotation speeds were predicted, and they showed that too much or too little volume of lubricant is undesirable and harmful. Consequently, the optimization of lubrication volume was designed by means of a response surface methodology, and an optimal lubricant volume was configured under a gear speed of 5260 rpm and immersion depth of 2.6 mm, accounting for 66.69% of the total volume.