Study on the Dynamic Characteristics of the Gear Lubrication Flow Field with Baffles and Optimization Design Strategies

The gear transmission system occupies a core position in mechanical equipment due to its numerous advantages such as high efficiency, high reliability, and long durability, making it an indispensable key component. Investigating the distribution mechanism of the two-phase flow field in gear transmission systems and its optimization design strategies is crucial for enhancing the efficiency and reliability of gearboxes. This paper couples the Lattice Boltzmann Method (LBM) with Large Eddy Simulation (LES) to construct a dynamic modeling and solution method suitable for the lubrication flow field of high-speed gears with baffles. The core objective is to explore the distribution mechanism and dynamic characteristics of the lubrication flow field in gears with baffles. Based on the LBM–LES coupled model, this paper sets up a two-phase flow dynamic model for the high-speed gear lubrication flow field. By conducting a detailed analysis of the dynamic evolution of the lubrication process in the gearbox with the presence of baffles, this study reveals the changing patterns of flow field dynamics under different flow velocities and configurations of mixing components. The research findings indicate that when the radial speed of the gears reaches 8 m/s, a stable oil film can be formed on the gear surface, which is crucial for ensuring smooth operation and reducing wear. Additionally, it has been confirmed that larger baffle diameters and hole diameters can effectively increase the enthalpy of the fluid, thereby optimizing energy transfer and thermal performance. However, it is noted that a larger baffle diameter is not always better; when it exceeds a certain limit, the performance improvement effect gradually diminishes, indicating the existence of an optimal baffle diameter value. By optimizing the design of the baffle, the flow characteristics and energy dissipation of the fluid within the gearbox can be controlled, improving thermal management and lubrication performance. These research findings provide valuable references for the lubrication design and optimization of gear transmission systems in high-tech fields such as aviation and aerospace. They can help relevant technicians gain a deeper understanding of the complex mechanisms involved in the lubrication process, allowing for the design of more efficient and reliable lubrication systems, effectively enhancing the performance of the entire transmission system, and promoting progress and development in related technological fields.