Simulation approaches for the study of the oil flow rate distribution in lubricating systems with rotating shafts

• Multiple reference frame approach provides reliable prediction of flow rate distribution. • Flow rate is lower at the outlet closest to the inlet. • Flow distribution is minimally affected by the shaft speed. • Better flow balance is achieved with low ratio of radial hole diameter to axial channel diameter. This study addresses the issue of predicting the distribution of lubricant flow through the outlets of a rotating shaft used in vehicle power transmission. A typical geometry with closely spaced rows of holes, suitable for the lubrication of multi-disk clutches, was considered. Both lumped parameter and computational fluid dynamics approaches were applied and compared. The test rig for model validation was designed with a variable speed shaft featuring an axial oil inlet and three equally spaced pairs of radial outlet holes. The main characteristic of the experimental facility is the possibility to selectively measure the flow rates through each outlet. It was found that the three-dimensional model based on the multiple reference frame approach provides a reliable prediction of how the flow rate is distributed. Generally, the flow rate is lower through the outlet closest to the inlet and is maximum at the farthest exit. The flow distribution is minimally affected by the shaft speed. The influence of geometric parameters on making the flow distribution more uniform was studied. It was found that a better flow balance is obtained with a low ratio between the diameter of the radial holes and that of the axial channel. The results obtained offer best-practice guidelines for accurately simulating comparable systems, in order to optimize reliability of the mechanical transmission and energy efficiency of the flow generation unit.