An Analysis Model for Predicting Windage Power Loss of Aviation Spiral Bevel Gears Under Optimal Injection Jet Layout

With the increasing rotating speed of aviation spiral bevel gears, the load-independent windage power loss caused by hydrodynamic behavior has a greater impact on transmission efficiency. An analytical model is established to predict the windage power loss of spiral bevel gears with oil injection lubrication. The improved model regards the total windage losses as the sum of oil-gas dragging effects on the tooth flank, toe/heel, circular cone surface, circumference of the teeth, and tooth root. Then the numerical method and analytical method are combined to calculate windage losses. A multi-objective NSGA-II optimization algorithm is used to optimize the jet layout parameters. The rationality and accuracy of this model are verified by comparing the calculation results of an example with data sets of existing experimental findings and computational fluid dynamics (CFD) simulation results. The calculation results show that compared with the tooth profile assumption method in the existing literature, the improved calculation formula of windage dragging effect on tooth flank can better reflect the influence of oil injection lubrication layout parameters on windage loss and make the windage loss calculation more accurate. Finally, the influence of gear body parameters, working conditions parameters, geometric parameters, and injection lubrication layout parameters on the windage loss is examined. This research provides a theoretical basis and methodological guidance for optimization design of reducing windage power loss.