AMESim Heat Generation Model

1. CAViDS Consortium AMESim Heat Generation Model A CAViDS Consortium Project Advisory Board Report August 24, 2011

2. CAViDS Consortium Project Objective • Develop AMESim heat generation modeling capability for gearbox systems which compares favorably with experimental results.

3. CAViDS Consortium Work Plan Phase 1: Obtain software and familiarize. (Complete) Phase 2: Model and correlate churning and gear heat generation and temperature rise. 1. Caterpillar FZG test stand model (Complete) 2. Eaton heavy duty transmssion (Underway) 3. Eaton medium duty transmission (Underway) 4. Caterpillar Axle model (Waiting for data)

4. CAViDS Consortium Technical Status 1.Correlated AMESim temp rise model with Caterpillar Dynasty model of FZG test stand Correlated AMESim temp rise model with Eaton MDT and HDT test data Correlated Changenet based spreadsheet no load loss prediction with MDT and HDT test data Compared AMESim and Changenet churning loss predictions Compared AMESim, LDP, Benedict Kelley, ISO and other sliding loss predictions Developed approach to incorporate churning, bearing, and synchro loss models into AMESim.

5. CAViDS Consortium Goals for Last Month • Incorporate synchro shear and bearing losses into AMESim • Develop axle churning loss model • Develop axle thermal model

6. CAViDS Consortium Last Month’s Accomplishments • Incorporated churning, bearing, and synchro shear loss models into AMESim • Got agreement with Caterpillar to proceed with axle thermal modeling

7. CAViDS Consortium AMESim No Load Loss Modeling Develop heat generation modeling capability for Eaton medium and heavy duty which accurately predicts no load losses and temperature rise on a spin test. Incorporate equations into AMESim.

8. CAViDS Consortium AMESim No Load Loss Sub-Modeling Passes key fluid parameter Uses heat generation equations

9. CAViDS Consortium AMESim No Load Approach • Used existing fluid properties submodel and choose specific parameter to extract (in submodel mode) • Used AMESet to develop heat generation submodel, using Changenet churning, bearing and synchro shear equations. Select in submodel mode. • Ran AMESim and heat generation to spread sheet under identical condtions (single component).

10. CAViDS Consortium AMESim No Load Approach • To model total transmission no load heat generation; • Replicate as many submodels for gear churning loss as required • Replicate as many submodels for bearing loss as required • Replicate as many submodels for synchro shear loss as required • This was not done based on the independent correlation done on • torque loss and temperature rise due to constant torque loss input

11. CAViDS Consortium Next Month • Develop axle churning loss model based on Caterpillar input • Develop axle thermal model based on Caterpillar input • Compare model to experimental data

12. CAViDS Consortium Notes • Software easy to use • LMS has great support • Capabilities will meet our needs • University license $3000 for year • Changenet churning loss calculations look promising • LDP mesh loss prediction easy to use – need development