CFD Untersuchung von im Ölbad rotierenden Zahnrädern mit Fluent CFD investigation of rotating gears in oil with Fluent
Paul Illg, Alexander Berg, Dmitrij Neufeld John Deere GmbH & Co. KG, Mannheim
P. Illg, A. Berg, D. Neufeld 2 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Content
John Deere – Today
Background & Objectives
Verification Procedure
Results
Conclusion
P. Illg, A. Berg, D. Neufeld 3 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Content
John Deere – Today
Background & Objectives
Verification Procedure
Results
Conclusion
P. Illg, A. Berg, D. Neufeld 4 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
John Deere Factory Mannheim and Bruchsal
Producing AG equipment since 1867
over 1.6 million tractors since 1921
2/3 of overall German tractor production
70 to 210 hp tractors (97/68/EC)
4,005 employees at the Mannheim site
1,375 employees at the Bruchsal site
Biggest John Deere factory outside of North America
P. Illg, A. Berg, D. Neufeld 5 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
6R Transmission - Power of Choice
PowrQuad Plus
AutoQuad Plus
DirectDrive AutoPowr
P. Illg, A. Berg, D. Neufeld 6 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Content
John Deere – Today
Background & Objectives
Verification Procedure
Results
Conclusion
P. Illg, A. Berg, D. Neufeld 7 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Background & Objectives Model Order Reduction: From Tractor to Component Test Rig
Tractor
Lots of different systems & circuits
Different focus & analysis goals
Gearbox
Lots of different - gear pairs - compartments - subsystems
Limited access for detailed analysis
Test Rig (iGSL)
- Plexiglas box
- Gear interaction - Splashing - Losses
- Oil level & prop. - Shields / Baffles
P. Illg, A. Berg, D. Neufeld 8 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Background & Objectives Model Order Reduction: From Tractor to Component Test Rig
Tractor
Lots of different systems & circuits
Different focus & analysis goals
Gearbox
Lots of different - gear pairs - compartments - subsystems
Limited access for detailed analysis
Test Rig (iGSL)
- Plexiglas box
- Gear interaction - Splashing - Losses
- Oil level & prop. - Shields / Baffles
Animation
P. Illg, A. Berg, D. Neufeld 9 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Background & Objectives Gearbox CFD Challenges
–Gear interaction
• Full, No, Partially
– Numerical approaches
• E.g. MRF, sliding & dynamic meshes
–Multiphase & free surface flow
• Mesh & time step size
• Numerical modelling
– Calculation time & Scalability
Rotating walls (w/o teeth) Truncated gears Shrinked gears
Gear interaction – dynamic mesh
Air
Oil
P. Illg, A. Berg, D. Neufeld 10 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Background & Objectives Gearbox CFD Challenges
–Gear interaction
• Full, No, Partially
– Numerical approaches
• E.g. MRF, sliding & dynamic meshes
–Multiphase & free surface flow
• Mesh & time step size
• Numerical modelling
– Calculation time & Scalability
Rotating walls (w/o teeth) Truncated gears Shrinked gears
Gear interaction – dynamic mesh
Air
Oil
Animation
Air
Oil
P. Illg, A. Berg, D. Neufeld 11 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Content
John Deere – Today
Background & Objectives
Verification Procedure
Results
Conclusion
P. Illg, A. Berg, D. Neufeld 12 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Verification Procedure Identify Dominant Influence Factors
Brainstorming sessions, team effort: collect
physical & numerical factors
Influence Factors
Main Factors
Personal screening identify & select factors with highest impact on
splashing & losses
DoE
Numerical screening CFD meets DoE which factor has
dominant influence on which answer?
P. Illg, A. Berg, D. Neufeld 13 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Verification Procedure Solution Concept: Design of Experiments (DoE)
CFD Run
Rotation
Gear model
Temperature
Oil level
Rot. Speed
Mesh size
Time step
Met-hod
1 -1 -1 1 1 1 1 2 0 0 0 0 0 0 3 1 1 -1 -1 -1 -1 4 -1 -1 0 0 -1 -1 5 0 0 -1 -1 1 1 6 1 1 1 1 0 0 7 -1 0 -1 -1 0 -1 8 0 1 1 1 -1 1 9 1 -1 0 0 1 0 10 -1 1 0 0 0 1 11 0 -1 -1 -1 -1 0 12 1 0 1 1 1 -1 13 -1 0 1 1 -1 0 14 0 1 0 0 1 -1 15 1 -1 -1 -1 0 1 16 -1 1 -1 -1 1 0 17 0 -1 1 1 0 -1 18 1 0 0 0 -1 1
Most important 8 physical & numerical factors:
–DoE considering factor interaction: 864 CFD runs not feasible
levels
L/R disc trunc shrink
low mid high
low mid high
low mid high
coarse mid fine
coarse mid fine
fast stable accurate
P. Illg, A. Berg, D. Neufeld 14 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Verification Procedure Solution Concept: Design of Experiments (DoE)
CFD Run
Rotation
Gear model
Temperature
Oil level
Rot. Speed
Mesh size
Time step
Met-hod
1 -1 -1 1 1 1 1 2 0 0 0 0 0 0 3 1 1 -1 -1 -1 -1 4 -1 -1 0 0 -1 -1 5 0 0 -1 -1 1 1 6 1 1 1 1 0 0 7 -1 0 -1 -1 0 -1 8 0 1 1 1 -1 1 9 1 -1 0 0 1 0 10 -1 1 0 0 0 1 11 0 -1 -1 -1 -1 0 12 1 0 1 1 1 -1 13 -1 0 1 1 -1 0 14 0 1 0 0 1 -1 15 1 -1 -1 -1 0 1 16 -1 1 -1 -1 1 0 17 0 -1 1 1 0 -1 18 1 0 0 0 -1 1
Most important 8 physical & numerical factors:
–DoE considering factor interaction: 864 CFD runs not feasible
– Screening DoE: Taguchi L18 Design
• Full orthogonality
• 18 Runs
Responses: • Power losses
• Oil behavior
• Calculation time
P. Illg, A. Berg, D. Neufeld 15 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Verification Procedure Numerical Modelling with ANSYS Fluent
–Meshing gear interaction:
• Rotating sliding & dynamic mesh zones vs. static zones.
– Solver Settings:
• Multiphase flow: Volume of Fluid (VoF)
• Turbulent, incompressible, isothermal
• 3 mesh sizes: 1,4~11 Mio Tets
• 3 sets of solution methods: fast/accurate/stable
• 3 time step sizes: CFL 0,2~14
Truncated Gears – Sliding Mesh
Interacting Gears – Dynamic Mesh
Shrinked Gears – Sliding Mesh
Animation
P. Illg, A. Berg, D. Neufeld 16 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Content
John Deere – Today
Background & Objectives
Verification Procedure
Results
Conclusion
P. Illg, A. Berg, D. Neufeld 17 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
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Results #1: Losses Pareto Chart: Dominant Factors
– Rot. speed dominant.
– Top 5 factors:
• Physical & numerical “pairs”.
– Findings:
• Solution methods & gear representation more important than mesh size & time steps.
• Oil level & temperature more important than rot. direction.
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0 2 4 6 8 10 12 14
Lo
sses
Velocity [m/s]
P. Illg, A. Berg, D. Neufeld 18 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Results #1b: Losses Top3 Solution Methods & Oil Level
– Solution Methods:
• Accurate method calculates slower but moment converges faster
• Methods focusing on calc. speed & stability 50% lower losses
–Oil Level:
• Losses increasing with oil level
• Same influence level as num. settings
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1 3 5 7 9 11 13 15 17 19 21 23 25
Losses
Revolutions [-]
Shrinked Gears: 600/1200 rpm
Set1_stable
Set2_accurate
Set3_fast
Accurate methods:
more conservative loss prediction & overall faster converged solution.
To decrease losses decrease oil level.
Air
Oil
P. Illg, A. Berg, D. Neufeld 19 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Results #1c: Losses Top5 Gear Representation & Oil Temperature
–Gear representation:
• Significant influence on losses
• considering gear interaction: Losses x6 Faster moment stabilization
–Oil temperature:
• Toil density & viscosity losses
Truncated Gears
Interacting Gears
Volume fraction [-]
Air
Oil
Animation
P. Illg, A. Berg, D. Neufeld 20 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Results #2: Oil Pumping Effect Pareto Chart: Oil Volume above Initial
– Rotation speed dominant
– Solution methods:
• Fast method pumping effect
–Gear representation:
• Not significant for pumping effect
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Dominant factor
Not significant
Shrinked Gears: 600/1200rpm
Truncated Gears: 1500/3000rpm
Isosurface: 50% oil Vol.fraction, colored by velocity [m/s]
Animation
P. Illg, A. Berg, D. Neufeld 21 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Results #3: Oil Splashing Intensity Pareto Chart: Max Oil Height
–Oil level dominant
• Oil level reduction less oil splashing
– Rot. speed & mesh size Top3
– Rot. direction & solution methods
• Not significant
Low oil level
Mid oil level
High oil level
Isosurface: 50% oil vol.fraction, High speed: 1500/3000 rpm
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Dominant factor
Not significant
P. Illg, A. Berg, D. Neufeld 22 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Results #4: Calculation Time Pareto Chart: Calculation Time per Simulated Second
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100%
Rela
tive C
oeffic
ient
Dominant factors
Less significant
–Gear representation & time step size dominant factors
• Dynamic mesh models need smallest time steps Calc. time 30x higher compared to truncated gears
• CFD cases w/o gear teeth accept biggest time steps Rotating discs fastest approach
DM: geom. limitation
meshes @2 timesteps
P. Illg, A. Berg, D. Neufeld 23 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Results #5: Calculation Time Pareto Chart: Calculation Time until Moment Stabilization
–DoE CFD runs: huge calc. time variation.
– Faster moment stabilization with more complex methods.
– Improvement of speedup & scalability desired!
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oeffic
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Dominant factors
P. Illg, A. Berg, D. Neufeld 24 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Content
John Deere – Today
Background & Objectives
Verification Procedure
Results
Conclusions & Outlook
P. Illg, A. Berg, D. Neufeld 25 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Conclusions
– Numerical models developed to use CFD in transient multiphase gearbox applications.
– Performed DoE to screen most important factors on oil splashing, losses & calculation time.
– Approaches with more physics and higher order solution methods are:
• More compute intensive, but show a faster moment stabilization.
• Show more realistic effects and are closer to literature results.
– Early design stages with simplified gears, detailed analysis needs more physics.
Volume fraction Air
Oil
Pressure
Animation
P. Illg, A. Berg, D. Neufeld 26 ANSYS Conference & 33rd CADFEM Users' Meeting
June 24 – 26, 2015, Messe Bremen |
Outlook
– Test rig investigations to receive known accuracy or deviation of stronger idealized models.
– Further investigations with numerical methods needed:
• Turbulence models & near wall treatment with boundary layers
• Surface tension models
– Speedup & Scalability improvements desired.
– Investigation of the interaction between the influencing factors.
– ANSYS Support extremely valuable in case of new methodology or any issues! Thank you!
Animation