Energy loss and mechanical efficiency forecasting model for aero-engine bevel gear power transmission.

• Numerical loaded tooth contact analysis for meshing interface. • Meshing interface state evolution under TEHL condition. • Non-Newtonian fluid ETHL model considering entrainment angle. • Separation flow method for the friction coefficient determination. • Energy loss and mechanical efficiency forecasting model. Energy loss and mechanical efficiency directly affect the service performance and reliability of aero-engine bevel gear power transmission, but there is currently a lack of effective diagnosis in early design stage due to the complex tooth meshing interface state evolution under the thermal elastohydrodynamic lubrication (TEHL) condition. A new energy loss and mechanical efficiency prediction model is proposed by using the improved TEHL analysis considering the entrainment angle and non-Newtonian fluid effect. Firstly, numerical loaded tooth contact analysis (NLTCA) is developed to determine tooth meshing kinematic relating to the entrainment and sliding states. Then, the entrainment angle is taken into account the Non-Newtonian fluid TEHL model and separation flow method is applied for friction coefficient solution. Finally, new energy loss and mechanical efficiency model is established by simulating the complex tooth meshing interface TEHL. This model is enabling ever-higher levels of aero-engine bevel gear production efficiency and design sustainability. It can provide an important access to geometric and physical assessments that can improve the energy generation, conversion, transfer and utilization of the whole aero-engine power transmission system. [Display omitted]. [ABSTRACT FROM AUTHOR]