Numerical Modeling of Churning Power Loss of Gear System Based on Moving Particle Method

Churning power losses are an important portion of transmission load-independent power losses, especially in high-speed condition and dip-lubricated gearboxes with high immersion depth. Generally, it is difficult to calculate the churning power losses due to the parameters of stirring oil and many other operating conditions. In this article, a method is proposed to determine the factors that influence churning power losses in gearboxes. Firstly, based on the moving particle semi-implicit (MPS) method, a numerical model of single-stage gears stirring oil is established. Then the accuracy of the established model is validated experimentally. Finally, the orthogonal simulation analysis is carried out to analyze the influence of gear rotation speed, tooth width, helix angle, immersion depth, and oil temperature on the churning power losses.