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An accurate simulation model of the lubrication system is essential for early design of the heavy truck transmission. In this article, a detailed computational method for the flow network analysis of the lubrication circuit is developed based on the hydraulic theory, and the flow resistance through the oil pipes and orifices is also taken into consideration. Then, the Next Limit Technologies’ XFlow, a potential new three-dimensional computational fluid dynamics software based on lattice Boltzmann method, is adopted to obtain the relationship between the oil delivery and the lubrication effect in the low-pressure capillary lubrication network of the rear auxiliary gearbox. To achieve the best overall lubricating performance of the flow network, the optimized design of the diameter for each oil supply orifice is determined by a detailed sensitivity analysis on the contribution of each parameter to the volumetric flow rate. The bench tests for the volumetric flow rate have been performed for validating the computation model by comparing the predicted volumetric flow rate through each oil supply bore with the experimental data at various pump speeds. The endurance tests have further conducted and the test results indicate a remarkable reduction in mechanical weariness when the best solution of the flow network design for the transmission lubrication system is adopted.

Optimized design of the flow network in the lubrication system for the heavy vehicle transmission