Tooth surface geometry optimization of spiral bevel and hypoid gears generated by duplex helical method with circular profile blade

In order to effectively improve meshing performance of spiral bevel and hypoid gears generated by the duplex helical method, the effects of straight lined and circular cutting edges profile on meshing and contact of spiral bevel and hypoid gears were investigated analytically. Firstly, a mathematical model of spiral bevel and hypoid gears with circular blade profile was established according to the cutting characteristics of the duplex helical method. Based on a hypoid gear drive, the tooth bearings and the functions of transmission errors of four design cases were analyzed respectively by the use of the tooth contact analysis(TCA), and the contact stresses of the four design cases were analyzed and compared using simulation software. Finally, the curvature radius of the circular profile blade was optimized. The results show that the contact stresses are availably reduced, and the areas of edge contact and severe contact stresses can be avoided by selecting appropriate circular blade profile. In addition, the convex and concave sides are separately modified by the use of different curvature radii of inside and outside blades, which can increase the flexibility of the duplex helical method.

Diagnosis and Design Improvement of the Internal Flow Field in an Automotive Cooling Fan Based on Boundary Vorticity Dynamics, Part Ⅰ: Blade Profile Scaling and Rotation

To optimize the aerodynamic performance of the automobile cooling fan(ACF), the internal flow field of the original fan was numerically simulated. According to the theory of boundary vorticity dynamics(BVD), the distribution laws of the boundary vorticity flux(BVF) on the blade surface and the circumferential vorticity(CV) at the wake plane of the fan were analyzed, and the underlying various negative factors, such as vortex shedding, separated flow and complicated secondary flow, on the fan blade surface and its dynamic source were diagnosed. Combined with the velocity triangle theory, the mathematical relationship between the BVF diagnosis and the geometrical characteristics of the blade profile(hereinafter referred to as profile) is used to guide the design improvement of the blade. The analysis found that at the same speed, the extension and rotation of the profile could match a smaller input torque at the same flow rate and pressure rise, thereby improving the efficiency of the fan. The test results confirmed the above conclusion. The peak efficiency of the improved fan has been increased by 2.3%, and the aerodynamic performance in the low-flow-rate has been improved. The conclusion of the study shows the applicability of the BVD theory in the diagnosis and design improvement of ACF internal flow.

Unsteady Inflow Effects on the Wake Shed from a High-Lift LPT Blade Subjected to Boundary Layer Laminar Separation

An experimental investigation on the near and far wake of a cascade of high-lift low-pressure turbine blades subjected to boundary layer separation over the suction side surface has been carried out, under steady and unsteady inflows. Two Reynolds number conditions, representative of take-off/landing and cruise operating conditions of the real engine, have been tested. The effect of upstream wake-boundary layer interaction on the wake shed from the profile has been investigated in a three-blade large-scale linear turbine cascade. The comparison between the wakes shed under steady and unsteady inflows has been performed through the analysis of mean velocity and Reynolds stress components measured at midspan of the central blade by means of a two-component crossed miniature hot-wire probe. The wake development has been analyzed in the region between 2% and 100% of the blade chord from the central blade trailing edge, aligned with the blade exit direction. Wake integral parameters, half-width and maximum velocity defects have been evaluated from the mean velocity distributions to quantify the modifications induced on the vane wake by the upstream wake. Moreover the thicknesses of the two wake shear layers have been considered separately in order to identify the effects of Reynolds number and incoming flow on the wake shape. The self-preserving state of the wake has been looked at, taking into account the different thicknesses of the two shear layers. The evaluation of the power density spectra of the velocity fluctuations allowed the study of the wake unsteady behavior, and the detection of the effects induced by the different operating conditions on the trailing edge vortex shedding.