We empower engineers by providing them with browser-based mesh-free CFD software to validate their designs.
We know that every use case is unique and every engineer faces different challenges. That's why we want to invite you to the free, non-binding workshop where we can find out if our software can help you solve your problems.
We will get back to you to learn more about your use case and to schedule the First Date - a web call.
We start by presenting Dive and the possibilities of our software. There will be time for discussion and questions.
If we both come to the conclusion that our product can help to solve your problems, we will move forward together to the next step - a free, non-binding workshop. There, we will dive deeper into your use case and test our software on your design. Let's get started!
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.
We will get back to you to learn more about your use case and to schedule the First Date - a web call.
We start by presenting Dive and the possibilities of our software. There is a place for a discussion and more questions.
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!
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!
Industrial Gearboxes.
Automotive Gearboxes.
Marine Gearboxes.
Aviation Gearboxes.
Roller Bearings.
Sufficient and reliable oil supply is essential in order 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. Furthermore, the lubricant’s additives play many different roles, ranging from corrosion inhibitor to antifoam to reliable abrasion setting.
Ensuring that all components are wetted properly is key, and it is critical to know early in your design process which regions are not sophistically lubricated. This should be known before you’ve built or even shipped your product. Why?
Your most precious resource is time. Minimize lost time by frontloading your development process with digital solutions. Frontloading also saves money, as we all know what a recall campaign of a whole gearbox series costs.
Bearings are the unnoticed stars in transmissions, always supporting the shafts by carrying axial and radial loads. Their durability and functionality must be reliable in all operating conditions. A major challenges for bearing lubrication is that many small surfaces are always in contact with the inner and outer rings. Analyzing the smallest fluid scales is critical and can be done effectively with particle-based fluid simulation.
LEARN MOREActive 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 an 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, is it even worth it to install the oil-pump or is a bath lubrication the most beneficial option after all?
General guidelines are acceptable, and your internal knowledge is sophisticated, but this topic becomes relevant every time you develop a new application, so evaluating these design possibilities beforehand will foster your strategic advantage in the market.
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 only leads to more issues: a blocked breather might reduce ventilation cooling, the cold start may not work as planned, or the lubricant properties may change drastically with higher or lower temperatures, causing the lubrication functionality to fail. Temperature effects are complex, and a reliable monitoring tool is essential.
Transmissions distribute excessive loads within your machinery by converting momentum and rotational speed to the desired ratio. For all mechanical systems, these processes come with unwanted heat generation due to the friction within the highly loaded contacting components, the squeezing of the
lubricant in between the contact zones, and the splashing of the lubricant-air mixture inside the gearbox.
Again, sufficient oil supply is critical, but an oversupply results in excessive losses. Progressive mechanical engineering designs target the highest possible energy efficiency and raw material sustainability, rendering conservative approaches as obsolete.
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 the power balance. The first step is to understand how much power is required, the next is to analyze it by component, and the last is to optimize the loss distribution on a component level.
Determining total churning losses and the loss distribution for each component may be difficult or impossible with experiments, but it is all possible with particle-based fluid simulation.
We use the integral boundary approach
which works directly 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 it 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, results are highly accurate. Accurate geometry means better results.
The rule of thumb is that windage phenomena becomes prominent at around 20(25) m/s pitch line velocity. At this velocity, it is necessary to use simulation in order to optimize your lubrication. 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 are deflected.
Our sophisticated multiphase approach has you covered whenever you analyze these situations.
Multiphase flows can be simulated in just a few clicks, as shown in this example video. Just 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!
Selecting the correct gear set for your application, defining the housing geometry, choosing the material and surface finishes. These are costly and critical parts 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.
Spur gears, helical gears, bevel gears, epicyclic gears, worm gears: the list goes on! Even complex setups can be analyzed through various interfaces.
Is dipping the gears into the oil sump not satisfying your needs? You can create a solid stream with a full cone or flat fan nozzle and even simulate moving oil nozzles.
What about other influential parameters like varying RPMs, low and high temperatures, thin and thick oils, too much or too little oil? These can all be defined within our tool.
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.
We can talk a lot about the gearboxes, but if you want to see real-life examples and success stories with our customers and partners, check out our articles.
Gearbox lubrication & churning
losses
Comparing simulation results to experimental data
Current challenges in wind turbine gearbox lubrication
Tell us about it and we will let you know if we can help you.
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.
Let's have a web call or exchange emails to talk about your use-case. We look forward to e-meeting you.
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.
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.
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.
