CFD Modelling and Numerical Simulation of the Windage Characteristics of a High-Speed Gearbox Based on Negative Pressure Regulation

Abstract

Windage power loss plays a leading role in the total power loss of high-speed gears, which seriously affects the transmission efficiency of gear systems and leads to high energy consumption. This paper proposes a negative pressure regulation method to reduce windage power loss. Based on the computational fluid dynamics theory, the flow field distribution and windage power loss in the gearbox under different negative pressure conditions are studied, and the effect of the negative pressure environment and speed on the windage power loss is obtained. In order to further save calculation costs, an optimization algorithm of the BP neural network based on a genetic algorithm is proposed to effectively predict the windage power loss. The results show that the high-speed airflow near the tooth’s surface will produce a large pressure moment, which is the main cause of wind resistance loss. The windage power loss increases with the increase in the negative pressure or speed of the gearbox, but the effect of speed is more obvious. The prediction results of the optimization algorithm are in good agreement with the finite element simulation data and the open literature, which can predict the best parameters for reducing windage power loss.