Investigating the Regulatory Mechanism of the Baffle Geometric Parameters on the Lubrication Transmission of High-Speed Gears

Under extreme operating conditions, the internal lubricating flow field of high-speed gear transmission systems exhibits a transient oil–gas multiphase flow, predominantly governed by cavitation-induced phase transitions and turbulent shear. This phenomenon involves complex mechanisms of nonlinear multi-physical coupling and energy dissipation. Traditional lubrication theories and single-phase flow simplified models show significant limitations in capturing microsecond-scale flow features, dynamic interface evolution, and turbulence modulation mechanisms. To address these challenges, this study developed a cross-scale coupled numerical framework based on the Lattice Boltzmann method and large eddy simulation (LBM-LES). By incorporating an adaptive time relaxation algorithm, the framework effectively enhances the computational accuracy and stability for high-speed rotational flow fields, enabling the precise characterization of lubricant splashing, distribution, and its interaction with air. The research systematically reveals the spatiotemporal evolution characteristics of the internal flow field within the gearbox and focuses on analyzing the nonlinear regulatory effect of baffle geometric parameters on the system’s energy transport and dissipation characteristics. Numerical results indicate that the baffle structure significantly influences the spatial distribution of the vorticity field and turbulence intensity by reconstructing the shear layer topology. Low-profile baffles optimize the energy transfer pathway, effectively reducing the flow enthalpy, whereas excessively tall baffles induce strong secondary recirculation flows, exacerbating vortex-induced energy losses. Simultaneously, appropriately increasing the spacing between double baffles helps enhance global lubricant transport efficiency and suppresses unsteady dissipation caused by localized momentum accumulation. Furthermore, the geometrically optimized double-baffle configuration can achieve synergistic improvements in lubrication performance, oil film stability, and system energy efficiency by guiding the main shear flow and mitigating localized high-momentum impacts. This study provides crucial theoretical foundations and design guidelines for developing the next generation of theory-driven, energy-efficient lubrication design strategies for gear transmissions.