Computational Modelling of Thermo-Elastohydrodynamic Lubricated Contacts

In current CONTACTLUB project, we envisage to develop reliable, accurate and experimentally well-validated computational models for dynamic Thermo-Elasto-Hydrodynamic Lubricated (TEHL) contacts. Particular focus lies on (i) the dynamic response of TEHL contacts to variable loads and velocities (oscillating motion, vibrations,…) and (ii) the influence of TEHL contact dynamics to structural transmission of vibrations and noise generation in multi-component assemblies.
The intended models include (i) detailed 3D CFD-FSI modelling and simulation of the TEHL contacts (UGent), (ii) derived meta-models for mapping the response of TEHL contact under dynamic operating conditions (UGent) and (iii) Efficient Flexible Multi-Body Models, incorporating TEHL meta-models and novel reduced-order models for the large-scale deformation, with the aim to asses NVH (KU Levuen). These models allow for fundamental analysis of highly-loaded lubricated machine-components in powertrains, taking into account the contact dynamics of bearings and gears.

The CFD-FSI TEHL models and the Flexible Multibody models will be validated by comparison with novel experimental data obtained on 2 test-rigs, i.e. respectively (i) a novel large-scale bearing test rig that that will be developed at UGent and instrumented using Fibre-Bragg sensor probes (VUB) for pressure, temperature and film thickness measurements, and (ii) an in-house gear test bench, incorporating controlled lubrication, with the aim to assess accurately the transmission error and subsequent NVH (KU Leuven).

The project scope answers to the need of the Flemish industry to gain more insight in lubrication of critical components. A significant contribution will be made in developing models and experimental validation for TEHL and NVH which can be incorporated in the design process or in fundamental or applied research questions. The results can be later on enriched by other multiphysics models e.g. for damage.