Experimental Study on Windage Power Loss of Fan Drive Gearbox System in GTF Engine
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摘要: 为研究风扇驱动齿轮箱风阻功率损失，基于齿轮风阻原始公式，阐明了油气比1∶34.25的通用风阻公式在风扇驱动齿轮箱中应用的局限性，除油气比外，内齿圈风阻计算公式需通过CFD仿真进行了修正；通过直接法测量GTF风扇驱动齿轮箱不同工况下的功率损失，结果表明：在轻载状态下齿轮箱总功率损失与转速成明显的指数关系，风阻损失占主导，理论值与实测值相差50 kW；不同转速相同扭矩状态下，修正理论功率损失和实测功率损失之间的差值由齿轮风阻引起，风扇驱动齿轮箱中拟合油气比约为1∶1.37；并给出齿轮箱风阻功率损失计算公式修正系数。Abstract: In order to study the windage power loss of Fan Drive Gearbox(FDGS), the limitation of the application of the general wind resistance formula with an oil air ratio of 1∶34.25 in the fan drive gearbox are clarified based on the original formula of gear windage power loss. Besides the oil-gas rate, the wind resistance formula of the inner gear ring windage power loss needed to be modified by using the CFD simulation. The power loss of FDGS under different working conditions was measured by using the direct method. The result show that the total power loss of the gearbox under light load has an exponential relationship with the rotational speed, and the windage power loss is dominant. The difference between the theoretical and the measured value is 50kW. Under the different rotational speeds and the same torque, the difference between the theoretical and the measured power loss is caused by the gear windage power loss, and the fitted oil-gas ratio in the FDGS is about 1∶1.37, in which the modified coefficient in the calculation formula of windage power loss is given.
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Key words:
- fan drive gearbox /
- windage power loss /
- oil-gas ratio
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图 5 工况1理论功率损失与实际功率损失对比
Figure 5. Comparison of theoretical and actual power loss for operating condition 1
图 6 工况2理论功率损失与实际功率损失对比
Figure 6. Comparison of theoretical and actual power loss for operating condition 2
图 7 工况3理论功率损失与实际功率损失对比
Figure 7. Comparison of theoretical and actual power loss for operating condition 3
图 8 CFD计算结果与工程计算结果对比
Figure 8. Comparison of CFD calculation and engineering calculation results
图 9 CFD计算结果与修正工程计算结果
Figure 9. Comparison of CFD calculation and modified engineering calculation results
图 10 工况1实际功率损失与修正理论功率损失
Figure 10. Comparison of actual and modified theoretical power losses for operating condition 1
图 11 工况2实际功率损失与修正理论功率损失
Figure 11. Comparison of actual and modified theoretical power losses for operating condition 2
图 12 油气比1∶1.37时工况2实际功率损失与修正理论功率损失对比
Figure 12. Comparison of actual and modified theoretical power losses for operating condition 2 at an oil-to-gas ratio of 1∶1.37
表 1 工况说明
Table 1. Description of operating conditions
工况 参数名称 转速/（r·min−1) 扭矩/Nm 1 低速变载 20 2000 ~ 26000 2 中速变载 5000 2000 ~ 26000 3 低载变速 500 ~ 5000 2000 
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表 2 工况1最大扭矩状态点各项功率损失对比
Table 2. Comparison of various power losses at the maximum torque state for operating condition 1
kW 参数 数值 参数 数值 $ {P_{\rm S12}} $ 2.65 $ {P_{\rm S23}} $ 1.0038 $ {P_{\rm R12}} $ 0.007 $ {P_{\rm R23}} $ 0.008 $ {P_{\rm{W}}} $ 0.000062 $ {P_{{\text{ bear}}}} $ 0.28
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表 3 工况2最大扭矩状态点各项功率损失对比
Table 3. Comparison of various power losses at the maximum torque state for operating Condition 2
kW 参数 数值 参数 数值 $ {P_{\rm S12}} $ 50.84 $ {P_{\rm S23}} $ 21.71 $ {P_{\rm R12}} $ 2.41 $ {P_{\rm R23}} $ 2.763 $ {P_{\rm{W}}} $ 5 $ {P_{{\text{bear}}}} $ 19.5
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表 4 齿圈转速
Table 4. Ring gear speed
计算点 转速/(r·min−1) 计算点 转速/(r·min−1) 1 500 5 1700 2 800 6 2000 3 1100 7 2300 4 1400 8 2600
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表 5 工况2修正理论功率损失与实际功率损失
Table 5. Comparison of modified theoretical and actual power losses for operating condition 2
状态点 理论功率损失/kW 实际功率损失/kW 误差/% 状态点 理论功率损失/kW 实际功率损失/kW 误差/% 1 72.72 68.82 −5.37 9 94.23 94.21 −0.03 2 70.80 70.66 −0.21 10 95.23 95.52 0.30 3 73.76 74.92 1.57 11 96.90 97.45 0.56 4 77.74 77.46 −0.37 12 98.88 99.76 0.88 5 78.47 78.34 −0.18 13 101.48 102.08 0.58 6 79.53 80.20 0.84 14 104.79 104.74 −0.05 7 79.14 81.26 2.67 15 110.36 109.21 −1.04 8 79.86 81.42 1.95 16 123.07 120.41 −2.17
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表 6 风阻功率损失计算公式修正系数
Table 6. Wind resistance power loss calculation formula correction factors
名称 修正前 修正后 油气比1∶k 1∶34.25 1∶1.37 内齿圈风阻转速系数 2.80 2.64
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