The shift toward electrification is pushing mechanical components to operate at higher rotational speeds, where fluid interactions significantly impact system efficiency due to load-independent power losses. While experimental methods and Computational Fluid Dynamics (CFD) simulations offer insights into these losses, the latter has become a fundamental design tool, especially for lubricated Rolling Element Bearings (REB) and gear systems. Recent studies highlight that solver selection, boundary conditions, and mesh quality, strongly affect simulation accuracy and computational cost. High-quality meshing, although time-consuming in the pre-processing phase, is widely recognized as a strategic investment, reducing computational efforts in simulations that can extend over weeks or months. This paper reviews and discusses meshing strategies for CFD simulations of lubricated mechanical components, focusing on open-source environments like OpenFOAM®. It examines techniques for modeling cylindrical roller bearings, tapered roller bearings, ball bearings, spur gears, helical gears, planetary gear systems, and bevel gears. It further presents mesh manipulation methods for rigid geometries under complex motions and systems involving time-dependent topological changes. A detailed literature review is provided, alongside original case studies demonstrating meshing methodologies. This work addresses a critical gap in CFD literature, offering a structured and practical guide to meshing lubricated mechanical systems.

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Meshing Strategies for CFD Simulations of Lubricated Mechanical Components in Open-Source Software

  • Lorenzo Maccioni,
  • Franco Concli

摘要

The shift toward electrification is pushing mechanical components to operate at higher rotational speeds, where fluid interactions significantly impact system efficiency due to load-independent power losses. While experimental methods and Computational Fluid Dynamics (CFD) simulations offer insights into these losses, the latter has become a fundamental design tool, especially for lubricated Rolling Element Bearings (REB) and gear systems. Recent studies highlight that solver selection, boundary conditions, and mesh quality, strongly affect simulation accuracy and computational cost. High-quality meshing, although time-consuming in the pre-processing phase, is widely recognized as a strategic investment, reducing computational efforts in simulations that can extend over weeks or months. This paper reviews and discusses meshing strategies for CFD simulations of lubricated mechanical components, focusing on open-source environments like OpenFOAM®. It examines techniques for modeling cylindrical roller bearings, tapered roller bearings, ball bearings, spur gears, helical gears, planetary gear systems, and bevel gears. It further presents mesh manipulation methods for rigid geometries under complex motions and systems involving time-dependent topological changes. A detailed literature review is provided, alongside original case studies demonstrating meshing methodologies. This work addresses a critical gap in CFD literature, offering a structured and practical guide to meshing lubricated mechanical systems.