【作者】 潘军；

【导师】 柴博森；

【作者基本信息】 吉林大学 ， 机械硕士（专业学位）， 2025， 硕士

【摘要】 齿轮变速箱作为车辆传动系统的核心动力传递部件,其运行稳定性与服役寿命直接决定了车辆传动系统的动态响应特性及全生命周期可靠性。随着电动化转型的加速推进,商用车正朝着高速化、电动化、智能化的方向快速发展。然而,电动集成化需求的增加导致高速齿轮变速箱的润滑空间被大幅压缩,这使得商用车在高速行驶过程中,齿轮变速箱容易出现润滑散热不良的问题,严重时甚至可能引发零件失效,进而带来安全隐患。针对上述问题,本文提出了基于润滑油定向调控的齿轮箱润滑散热优化策略,并通过三阶段递进研究实现性能优化。论文采用“理论建模,数值仿真,试验验证”的闭环研究方法,主要研究内容包括:(1)齿轮传动系统多维集成热流耦合建模基于热网络法的基本原理,结合理论计算与数值仿真方法,构建了齿轮箱热力学模型,经试验验证,该模型展现出较高的预测精度。同时,结合计算流体动力学理论,构建了齿轮系统热流耦合数值模型,将一维产热计算模型与三维流场仿真模型进行有机整合,实现了热源与流场的动态耦合建模。这一方法突破了传统单一物理场分析的局限性,精准再现了齿轮传动系统运行过程中两相流场结构与温度场分布的动态演化过程。(2)齿轮系统润滑油路定向调控理论及结构优化为了提升齿轮润滑与传热的双重性能,基于齿轮系统热动力学特性与流体力学行为的耦合机制,提出了润滑油路定向调控的理论框架。在此框架基础上,设计扰流结构,成功实现了润滑介质流动路径的定向调控,使齿面油液体积分数和对流换热系数大幅提升。基于扰流结构对润滑油路定向调控的作用机理,深入分析了其结构参数对扰流性能的影响,并建立了扰流结构优化模型。通过运用遗传算法对扰流结构进行多目标优化设计,进一步显著提升了齿轮箱的润滑散热性能。(3)齿轮箱油位与扰流结构协同优化基于齿轮箱功率损失和润滑散热性能的综合分析,本文深入探讨了润滑油量对系统性能的影响机制。通过对比不同油位高度的实验数据,系统研究了润滑油量对齿轮箱润滑散热性能的直接作用规律。研究结果表明,在添加扰流结构的情况下,当油位高度为80 mm时,齿轮箱的润滑散热性能显著优于未添加扰流结构且油位高度为95 mm的工况。这一发现为优化齿轮箱润滑散热性能提供了重要的理论依据和实践指导。更多还原

【Abstract】 As a core power transmission component in vehicle drivetrains,the gearbox’s operational stability and service life directly determine the dynamic response characteristics and lifecycle reliability of the vehicle drivetrain system.With the accelerated transition to electrification,commercial vehicles are rapidly evolving towards higher speeds,electrification,and intelligence.However,the increasing demand for integrated electrification has significantly compressed the lubrication space of high-speed gearboxes,leading to inadequate lubrication and heat dissipation during high-speed operation.This issue can potentially cause component failure and pose safety risks.To address these challenges,this paper proposes a lubrication and heat dissipation optimization strategy for gearboxes based on directional oil flow regulation,implemented through a three-stage progressive research approach.The paper adopts a closed-loop research methodology of"theoretical modeling,numerical simulation,and experimental validation,"with the main research contents as follows:(1)Multi-dimensional Integrated Thermal-Fluid Coupling Modeling of Gear Transmission SystemsBased on the basic principle of the thermal network method,a thermodynamic model of the gearbox is constructed by combining theoretical calculation and numerical simulation methods,and the model shows high prediction accuracy after experimental verification.At the same time,combined with the theory of computational fluid dynamics,a numerical model of heat-fluid coupling in gear system is constructed,which organically integrates the one-dimensional heat production calculation model with the three-dimensional flow field simulation model,and realizes the dynamic coupling modeling of heat source and flow field.This method breaks through the limitations of the traditional single physical field analysis,and accurately reproduces the dynamic evolution of the two-phase flow field structure and temperature field distribution during the operation of the gear transmission system.(2)Directional Regulation Theory and Structural Optimization of Gear System Lubrication Oil PathsIn order to enhance the dual performance of gear lubrication and heat transfer,a theoretical framework for the directional regulation of the lubricant flow path is proposed based on the coupling mechanism between the thermodynamic properties of the gear system and the hydrodynamic behavior.On the basis of this framework,the design of spoiler structure successfully realizes the directional regulation of lubricant flow path,so that the volume fraction of oil on the tooth surface and the convective heat transfer coefficient are greatly improved.Based on the mechanism of the perturbation structure on the directional control of the lubricant path,the influence of its structural parameters on the perturbation performance is analyzed in depth,and the optimization model of the perturbation structure is established.The multi-objective optimization design of the spoiler structure by using genetic algorithm further significantly improves the lubrication and heat dissipation performance of the gearbox.(3)Synergistic Optimization of Gearbox Oil Level and Flow Disturbance StructureBased on a comprehensive analysis of gearbox power loss and lubrication-heat dissipation performance,this study thoroughly investigated the impact mechanism of lubricant volume on system performance.By comparing experimental data at different oil level heights,the direct influence of lubricant volume on the gearbox’s lubrication and heat dissipation performance was systematically studied.The results indicate that with the addition of the flow disturbance structure,the lubrication and heat dissipation performance of the gearbox at an oil level height of 80 mm is significantly superior to that at 95 mm without the disturbance structure.This finding provides important theoretical and practical guidance for optimizing the lubrication and heat dissipation performance of gearboxes.更多还原