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Prediction of the oil accumulation on the spinning wheel on the right side of the axle assembly

ㆍ Product: Drive-Axle

ㆍ Analysis Goal: Predicting the shape of the oil band on spinning wheel to match physical testing

Based on Solution brief of Drive-Axle simulation - powertrain simulation - lubrication simulation - Dana Incorporated

Download PDF File about lubrication simulation (Click)

In physical testing the thickness of the fluid film that formed on a spinning wheel of an axle assembly had a distinct shape. A virtual model using Particleworks was established which reproduced the shape of the oil band correctly.

Process for Oil Churning and Lubrication Simulation

① Creation of the simple 1-chamber model to verify the possibility of reproduction of the oil band

② Simulation of the 1-chamber model and oil model using the fluid particles

③ Model tuning to find the maximum size of the particles to reproduce the oil band to reduce the simulation time

④ Establishing of the 3-chamber model after verifying that the oil band is reproduced with 1.3M particles

⑤ Simulation with 7M particles which takes 12 days without GPU

⑥ Model optimization to finish the simulation within 1~2 days with 2 GPUs

Key Technologies for Analysis

ㆍ Highly precise fluid modeling according to the characteristics of oil (Particleworks)

ㆍ Selection of the optimal size of the particles to reduce the simulation time

ㆍ High-speed particle simulation using GPU technology

Comparison Between Simulation Results and Tests Showing the Oil Band**

Toolkits for Oil Churning and Lubrication Simulation

ㆍParticleworks Interface

ㆍParticleworks

Customer Challenges

• Need for a CFD tool to reproduce the oil film deposition on the spinning component

Solutions

• Design improvement and verification using the virtual model which can reproduce the shape of the oil band caused by Oil Churning

• Visualization and quantitative analysis using Particleworks CFD ( details on Particleworks )

Outcome

• Dynamic behavior of lubrication oil and oil churning could be reproduced through simulation

• Lubrication oil-band caused by oil churning reproduced by the simulation well matched with the experimental data so that in the future, the drag could be predicted using a virtual model

• Various designs can be tested virtually and the opportunity for design improvements can be identified

Other Application Related to Lubrication, Oil Churning, Oil Sloshing

◀ Analysis of changes in load torque according to the difference in temperature of lubrication oil

ㆍRelationship between viscosity and load torque according to the temperature of lubricating oil after turning off the engine input torque

ㆍAnalysis of difference in reduction of speed according to lubrication status between the states that have different temperatures (viscosity)

ㆍOil churning

◀ Analysis of the reduction gear train which takes into consideration the viscosity of lubrication oil

ㆍVisualization of the lubrication oil spray and oil churning which was not possible until now

ㆍThe effect of the gear output according to the load of oil viscosity can be designed to be closer to reality

◀ Behavior analysis of lubrication oil spray inside the differential gearbox

ㆍAnalysis of load torque when viscous fluid (lubrication oil) has been added to the differential gear train robot

ㆍOil churning inside the differential gearbox could be visualized

(This technology is often used for drivetrain and powertrain simulation)