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Thanks for your interest in the Dive Experience!

We provide browser-based mesh-free CFD software to empower engineers to validate their designs.

We know that every use case is non-identical ​and each engineer is facing different challenges. That's why we want to invite you to the free non-binding workshop where we can find out if our product can solve also your problems.

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  1. Fill up the form

    We will get back to you to learn more about your use case and to schedule the First Date - a web call.

  2. The First Date

    We start by presenting Dive and the possibilities of our software. There is a place for a discussion and more questions.

  3. The Workshop with the Free Demo

    If we get together the conclusion that our product can solve your problems, we forward together to the next step - a free non-binding workshop. There we can dive deeper into your use case and test the software in real life. Let's talk!

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This is the first step in the Dive Experience Journey!

FIRST CALL OR EMAIL

Schedule a call with our engineer Yannick or if you prefer, write an email. We are excited to hear about your use case!

DRIVETRAIN LUBRICATION

Nowadays there are many different gearboxes on the market with more and more sophisticated designs.

Industrial Gearboxes.

Automotive Gearboxes.

Marine Gearboxes.

Aviation Gearboxes.

Roller Bearings.

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Prediction of oil distribution

Sufficient and reliable oil supply is vital to avoid gear and bearing damage under various operating conditions. The aim is to create a thin oil layer separating two components, thus minimizing wear, friction and excessive heat generation.

The thermal management of the component is equally important for a long-lasting component. Lastly, the lubricant’s additives play dozens of roles ranging from corrosion inhibitor, antifoam to reliable abrasion setting.

Accelerate your simulation routine from weeks to

days

Wetting analyses

It is key to ensure that all components are wetted properly, and even more critical to know early in your design process, which regions are not sophistically lubricated. And you definitively want to know this before you’ve built or even shipped your product. Why?

Your most precious resource is time that will be minimized with frontloading your development process by digital solutions. Your second-important good is money and we all know what recall campaign of a whole gearbox series costs.

Roller Bearing Example

Bearings are the unnoticed stars in transmissions, always supporting the shafts by carrying axial and radial loads. Their durability and functionality must be secured in all conditions as well. The challenges for bearing lubrication are that many small surfaces are always in contact with the inner and outer ring. - Analyzing the smallest fluid scales is mandatory!

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Active lubrication

Active lubrication is an excellent method to precisely adjust the oil supply to the areas where it is required and avoid the costly churning of your high-speed gears through the oil bath. But which nozzles should you use to optimize the oil jet impingement on the gear teeth surface?

Shall I use a solid stream, full cone or flat fan nozzle? And, eventually, is it worth to install the oil-pump or is a bath lubrication beneficial after all?

General guidelines are acceptable, and your internal knowledge is sophisticated, but this topic becomes important every time you develop a new application, so evaluating these design possibilities beforehand fosters your strategical advantage on the market.

Thermodynamics

It’s no secret that mechanical components last longer if they stay cool. But the story is more diverse for gearboxes: The mechanical engine power is partially converted into heat while being transformed at the gear stages – components become hotter, and their structure becomes weaker. How to transport this heat to the ambience? - With the lubricant! Easy, right?

But we all know that too much oil does not help, a blocked breather might reduce ventilation cooling, the cold start does not work as planned or the lubricant properties change too much with higher or lower temperature and the lubrication functionality fails. Temperature effects are complex, and a reliable monitoring tool is gold.

Efficiency optimization

Transmissions distribute excessive loads in your machinery by converting momentum and rotational speed to the desired ratio. As for all mechanical systems, these processes come with unwanted heat generation due to the friction within the highly loaded contacting components, squeezing of the
lubricant in between the contact zone and splashing the lubricant-air mixture in your gearbox.

Again, sufficient oil supply is critical, but an oversupply results in excessive losses. Progressive mechanical engineering designs target on the highest possible energy efficiency and raw material sustainability, which renders conservative approaches as overdue.

If we make all German wind turbine gearboxes 1% more efficient, it can save electricity for more than

670 000

people¹

Total & Local Power Loss

Especially for situations where rotational speed is high and load is low (like driving on the highway in the top gear), powering the lubricant’s motion becomes prominent in your power balance. The first step is to understand how much power is required, the next is to analyze it component-wise and the last to optimize the loss distribution on a component level.

How do we do it?

We are using the integral boundary approach
which directly works with the triangle surface
mesh. This makes it possible to accurately
represent the gears and the meshing zone.

Look at the video showing how easy is to upload
a standard STL file
and set the movements. On
top of that, you can use Python script to
automate the process
.

Thanks to the triangle-based boundary conditions, we are highly accurate. Accurate geometry = better results.

¹ Gross electricity consumption per capita in Germany | The overall power output of all onshore wind turbines in Germany

Complex multiphase flows

Why does it matter?

The rule of thumb is that windage phenomena become prominent at around 20(25) m/s pitch line velocity – so you need to resolve them with your simulation tool as well! Why is that so?

First, larger inertia of the oil phase during the gear rotation leads to the oil being thrown of radially and, second, an air cushion is formed in between gears teeth. With the air shielding the gear, oil in the bath as well as airborne oil droplets will be deflected.

No worries, our sophisticated multiphase approach has you covered whenever you analyze these situations.

How do we do it?

In our software, multiphase is just a few clicks away like in the example we show on the video. You add air as a second filling, move the seed point to desired space and that's it. If you want to see particles, click discretize.

Have a look at how the oil is mixing with the air and compare with your single-phase results!

ANY TYPE OF GEARBOXES

Selecting the correct gear set for your application, defining the housing geometry, choosing the material and surface finishes. This is a costly and critical part of your work, and the final designs vary a lot! What do they all have in common? - A lubrication system! The advantage of CFD? It gives you the power to analyze every lubrication system independent of the chosen gear set.

Various Gearbox Types

Spur gears, helical gears, bevel gears, epicyclic gears, worm gears: The list goes on! Even complex setups can be realized through various interfaces.

Dip & Jet Lubrication

Is dipping the gears into the oil sump not satisfying your needs? You can realize a solid stream, full cone or flat fan nozzle and even moving oil nozzles.

Physical Material Parameters

What about other influencing parameter like varying RPMs, low and high temperatures, thin and thick oils, too much or too little oil?

Have a look at the oil squeezing between the teeth. The fluid is radially thrown away by the wheel and the surface tension determines the flow pattern. Beautiful.

STORIES

We can talk a lot about the gearboxes here, but if you want to see real-life examples and success stories with our customers and partners, you definitely should read our articles.

DO YOU HAVE A DIFFERENT USE CASE IN MIND?

Tell us about it and we will let you know if we can help you.

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HOW TO GET STARTED

Sound interesting? We would love to get in touch with you to provide more information about our product and services and figure out how we can best serve you. Click below to get in touch.

First Date

Let's have a web call or exchange emails to talk about your use-case. We look forward to e-meeting you.

GET IN TOUCH
01

FREE Workshop

If you liked our first date, in the next step you can participate in a free, non-binding workshop where we will show you how our software works on your unique case.

02

Trial

If you want to dive a little bit deeper, you can begin a 3-month paid trial to test our software in your daily engineering life, supported by a fully dedicated customer success engineer.

03

Subscription

When the trial ends and you're left wanting more, you can choose a subscription option that suits your requirements and continue creating epic stuff.

04
HOW TO GET STARTED

Do you have more questions?

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