Modelling and Experimental Study of Power Losses in Toothed Wheels

In recent decades, the request for more efficient performances in the aeronautical sector moved researchers to pay particular attention to all the related mechanisms and systems, especially with respect to the saving of power. In this context, the bearing modeling and design, as well as gear coupling, play a fundamental role. Moreover, the need for low power losses also concerns the study and the implementation of advanced lubrication systems, especially for high peripheral speed. With the previous aims, this paper presents a new validated model for toothed gears, added to a bearing model; with the link of these different submodels, the whole model describes the system’s dynamic behavior, taking into account the different kinds of power losses (windage losses, fluid dynamic losses, etc.) generated by the mechanical system parts (especially rolling bearings and gears). As the bearing model, the proposed model is characterized by high numerical efficiency and allows the investigation of different rolling bearings and gears with different lubrication conditions and frictions. A comparison between the experimental and simulated results is also presented in this paper. The analysis of the results is encouraging and shows a good agreement between experiments and model simulations, with particular attention to the power losses in the bearing and gears.