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Methods of Computational Fluid Dynamics for

a CVT Transmission Lubrication System of
Agricultural tractor

Conference Paper · March 2014

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 The 9th International Fluid Power Conference, 9. IFK, March 24-26, 2014, Aachen, Germany

Methods of Computational Fluid Dynamics for a CVT Transmission Lubrication

System of Agricultural Tractor

Pietro Marani*, Cristian Ferrari*, Roberto Paoluzzi*, Cantelli Stefano**

IMAMOTER - C.N.R. Institute for Agricultural and Earth-moving Machines of the Italian National Research
Council, via Canal Bianco 28, 44124 Ferrara, Italy*
E-Mail: p.marani@imamoter.cnr.it, c.ferrari @imamoter.cnr.it

CNH Product Development, viale delle Nazioni 55, 41100 Modena, Italy**

In this paper, a Method of Analysis based on Computational Fluid Dynamics is presented to evaluate the
behaviour of a lubrication circuit of a CVT gearbox. The study of the lubrication in gearboxes is an important
issue in off-road machines design because reliability depends mostly from lubrication performance, as well as
machine lifetime and overall energy efficiency of the transmission. In the paper the methodology will be
presented step by step and finally a complete map of operation condition will be disclosed. The result will be
contextualized commenting the fluid dynamics phenomena involved and the influence parameters on flow rate
distribution.

Keywords: Hydraulic CFD, Lubrication Systems, Off Road Vehicles Transmissions

Target audience: Mobile Hydraulics, Agricultural Machinery, Transmission Industry

1 Introduction
The paper focus on the lubrication circuit of a CVT (Continuously Variable Transmission) Power Splitting
Transmission. This kind of architecture offers the possibility to obtain a zero output speed with a non-zero input
one; and is obtained by coupling a Continuous Variable Unit, a Planetary Gear Train and a fixed ratio gear. The
total power is split into two parts, one flowing through a constant ratio mechanical path and one through either
the Continuous Variable Unit. In general Continuous Variable Unit have a lower efficiency compared to the
constant ratio path, thus, adopting power split CVT architectures, their negative effects in terms of power
dissipation will influence a reduced amount of total power; nonetheless a continuously variable output speed can
be obtained over a wider speed range, in particular with multiple-range architectures. As a main consequence,
power split CVTs present an overall efficiency higher than that of a "direct" CVT, due to the higher efficiency of
the mechanical part.

The object of this study is an Input Coupled CVT Transmission in which the input power from endothermic
motor is connected to the solar shaft, the output to the satellite Carrier and the Continuously Variable Unit to the
External Ring Gear. The different Power Split and CVT architectures are analyzed in [1] and [2].

Several studies are found in the literature concerning power losses classification and determination, Ryu et al.
[3], who determined power losses in a mechanical transmission, [4] noted that Power loss reduction at the end of
the power train has a large impact on overall optimization, although absolute efficiency in gearboxes and rear
axles is already high, In power-shift and CVT transmissions, losses can be higher [1, 2]. Besides operating
conditions and internal housing design power losses in a gearboxes are mainly related to lubricant viscosity and
density [5]. B-R Hohn et al [6] investigated influence factor on gearbox power loss and and they saw that In
some applications only the simple change to a highly efficient lubricant can save some 20% power loss
 The 9th International Fluid Power Conference, 9. IFK, March 24-26, 2014, Aachen, Germany

Gear power losses are strongly related to lubrication, with those load dependent coming from the frictional
effects in the lubricant film and those load independent mainly deriving from squeezing, churning and windage
effects.

Analytical models of lubrication system have been studied by Robert S. LO [7], in 1971, Neu and Wade [8], in
1977, represented the entire engine lubrication system by a series-parallel network of flow passages and flow
elements. Mian [9], in 1997 a developed a design methodology for pump sizing and flow passage balance
applicable to variety of lubricated circuit. S.M. Chun et al. [10, 11], in 2000, developed a parametric model for
studies various configuration in terms of volumetric flow rate and pressure of engine lubrication systems. Felix
Klingebiel and Uwe Kahlstorf [12], in 2000, proposed the use of 1-D fluid flow models to predict the engine
lubrication system behavior.

Marchesse et al. [13], on the basis of a state of the art on the application of CFD to gear power losses, applied
CFD models to study windage losses of gears and have validated their results by means of experimental tests.
Hill et al. [14] studied trough CFD simulations the influence of different shrouding configurations on the
windage power losses. Diab et al. [15] present a number of preliminary experimental and theoretical findings on
the prediction of windage losses. Concli et al. [16 to 18] applied CFD models to study oil squeezing power losses
of gears and churning power losses of planetary speed reducers and have validated their results by means of
experimental tests.

Figure 1: Hydraulic Circuitry of a Modern Agricultural Tractor

From this literature analysis it has been noted, that while many lubrication issues have been deeply investigated,
the problem of flow distribution in the lubrication circuit hasn’t still been systematically approached with CFD
analysis.

The study of the lubrication in gearboxes is an important issue in off-road machines design because reliability
depends mostly from lubrication performance, a bad lubricated gears and bearings tend to overheat and grip
moreover the increase of wear dramatically reduces machine lifetime.

In the other hand an excess of lubrication affect the energy efficiency of the transmission in two ways: first the
hydraulic pump has to discharge higher flow rate than necessary, second the losses due to oil splashing and
squeezing increase.

The industrial approach on a such critical issue is mostly quite traditional and is still based on practice and on
trial and error method (which involve several prototype adjustments and extensive physical tests).

On the other hand the lumped element models approach is not always effective, mainly because of the
complexity of the geometry and of boundary conditions (i.e. rotating complex shape volumes, air inclusion, etc.).

A CFD approach is proposed here to characterize the flow field in the lubrication circuit. In order to accomplish
the goal, some challenging issues were encountered such as the architectural complexity due to the large number
of fluid paths and outlets, the critical meshing phase caused by the geometrical complexity and the difficult
choice of numerical boundary in order to reflect at best the actual conditions of the physical behavior.
 The 9th International Fluid Power Conference, 9. IFK, March 24-26, 2014, Aachen, Germany

In this paper an analysis method is outlined and different operating conditions were tested; and finally a
complete map of operation condition is obtained. The result are contextualized commenting the fluid dynamics
phenomena involved and the influence parameters on flow rate distribution.

2 Fluid Model

A preliminary analysis of the circuitry is an essential phase of the project. The tractors transmission is an
extremely complex assembly composed by hundreds of components. The lubrication circuit reflecting this
complexity has a large number of hydraulic consumers connected by a large network of conduits.

The most suitable strategy to split in various parts the transmission and concentrate the analysis on the single
parts one by one. If the mapping of every part is thorough it would be possible to study then the entire
lubrication distribution.

Figure 2: Fluid Domain of Primary Shaft Lubrication System

In this paper the CFD analysis of primary shaft will be presented. The primary shaft Architecture is formed by an
internal shaft connecting to endothermic motor, an external hollow shaft connecting to solar gear, a Planetary
Carrier connected to the output.

The Fluid Domain is formed by three tubular sections which side surfaces are corresponding to rotating shaft
faces and which the most inner is connected to the inlet radial pipe, these sections are connected to each other
by radial channels and to the components to lubricate by 19 radial outlet ducts.

To define stationary and moving parts the computational model surfaces have been divided in four sets; a
stationary one integral to gearbox carter (the outer surfaces and inlet pipe), the inner shaft surfaces, the hollow
solar shaft surfaces and finally the planetary carrier surfaces.
 The 9th International Fluid Power Conference, 9. IFK, March 24-26, 2014, Aachen, Germany

Figure 3: Definition of Stationary and Moving Surfaces

3 Generation of the Mesh

One of the most important and time-consuming tasks in the process of a CFD simulation is the generation of the
computational grid. A hybrid tetrahedrical and prismatic mesh was chosen, prismatic elements were used to
better describe the viscous wall region. The best compromise between quality of the mesh (distortion of the
elements), number of elements were found providing that even in the most narrow gaps a minimum of 6
prismatic layers is generated.

Figure 4: Mesh Obtained

The following Table synthetize the characteristics of the mesh obtained.

Number of Elements 1940699

Number of Tetrahedra 575134

Number of Prisms 575134

Number of Piramids 37340

Number of Surface Faces 477636

Number of Nodes 660653

Table 1: Characteristics of Mesh Obtained.

 The 9th International Fluid Power Conference, 9. IFK, March 24-26, 2014, Aachen, Germany

4 Simulation Set-Up

The numerical simulations were carried out with the commercial CFD code ANSYS CFX 14.0. The code solves
the 3D Reynolds-averaged form of the Navier-Stokes equations by using a finite-element based finite-volume
method. A second-order high-resolution advection scheme was adopted to calculate the advection terms in the
discrete finite-volume equations. The simulations were performed in steady state conditions.

The simulation set-up is an essential step toward reliable results, in the next paragraph it will be shown the
correct setting of boundary conditions, Fluid Characteristics and Turbulence mode.

4.1 Boundary Conditions

First the operating conditions were set on Surface Faces imposing the correct rotational speed on shafts’ walls
and stationary characteristic to carter and inlet pipe’s surfaces.

On all outlets were imposed the same static pressure condition because they all are connected to atmospheric
pressure both directly, both trough components like rolling bearings that presents Flow Areas of several order of
size bigger than lubrication pipes diameters.

On inlet a set of different static pressures were imposed to evaluate the behavior of the system under different
pressure drops.

The simulations were isothermal so the fluid in each simulation keeps a constant temperature, density and
viscosity. The denomination of fluid used is M2C 134 D that is a multifunctional mineral oil that supplies both
high pressure hydraulic implements both low pressure and lubrication circuits.

Inner Shaft Solar shaft Carrier

Case rev/min Rated Speed/Max Speed Rated Speed/Max Speed
1 1800 1,00 0,00
2 1800 0,95 0,11
3 1800 0,90 0,21
4 1800 0,85 0,31
5 1800 0,80 0,42
6 1800 0,77 0,49
7 1800 0,73 0,56
8 1800 0,70 0,64
9 1800 0,66 0,71
10 1800 0,63 0,78
11 1800 0,60 0,85
12 1800 0,56 0,93
13 1800 0,53 1,00

Table 2: Rotational Velocity of ShaftsConditions.

To characterize the Flow distribution to hydraulic consumers a large amount of simulation were performed
mapping the flow balance in reason of the three working operative variables:

• Temperature of Working Fluid

• Rotational Speed of Shafts

• Pressure Drop between inlet and outlets

 The 9th International Fluid Power Conference, 9. IFK, March 24-26, 2014, Aachen, Germany

The three temperature chosen are a minimum temperature corresponding to a winter cold starting of 0°C, a
medium working temperature of 60°C and a maximum allowed temperature of 90°C, the corresponding
viscosities are respectively 550 cSt, 29 cSt and 12.5 cSt.

A set of 8 pressure is drops are imposed with a range comprised between 0,5 and 4 bar and a step of 0,5 bar.

The Rotating Speed Condition is represented in the table 2.

4.2 Turbulence model

The criteria that influence the choice of turbulence models are essentially the physical nature of the problem, the
expected quality of the results and, moreover in industrial applications, the computational effort.

In this work, two turbulence models were used and compared. When oil temperature is 0 °C the Reynold
Number is less than 90 consequently a laminar turbulence model was imposed, instead when oil temperature is
60 and 90 °C the Reynold Number exceeds 400 on many parts of fluid domain a BSL turbulence model was
imposed. It has to be considered in fact that the rotating movement of the shafts increase the turbulence of the
fluid, for this reason the Laminar-Turbolent Transition Reynolds Number is lower than in stationary case.

The BSL model is an hybrid turbulence model in which a blending function F1 is used for gradual switching
from the k-ε model to the k-ω model. The function F1 changes gradually from unity at the walls to zero outside
the boundary layers. This should take advantage of the convenient features of both models, that is k-ε robustness
and fast converging features and k-ω near wall resolution.

5 Basic Physical Phenomena Involved

Basically three physical phenomena must be considered to explain the physical behavior of the oil flow in this
problem: the pressure differentials are determined by Turbulent Losses, Laminar Losses and Centrifugal Forces.

In every condition the flow distribution can be explained by the combined effect of these three phenomena and
in particular conditions some phenomena is prevalent with respect to the others, for example at low temperature
the laminar losses prevail, at high temperature the flow is mostly turbulent, at low pressure drops the Centrifugal
Forces are the key factor that determines the flow distribution.

5.1 Laminar Losses

The distributed laminar losses in conduits are proportional to flow velocity, to viscosity and Length.

𝑤∙𝐿∙𝜇 (1)
∆𝑝 = 8 ∙
𝑅2
64 𝐿 𝑤 2 (2)
∆𝑝 = ∙ ∙ ∙𝜌
𝑅𝑅 𝐷 2
Substituting in (1) with the definition of Reynolds Number, equation 2 is obtained

5.2 Turbulent Losses

The turbulent losses, have a weak dependency on viscosity, are proportional to square of flow velocity and to
the friction factor that basically depends on geometry.

𝑤2 (3)
∆𝑝 = 𝛽 ∙
2
 The 9th International Fluid Power Conference, 9. IFK, March 24-26, 2014, Aachen, Germany

5.3 Centrifugal Pressure Differential

In a rotating dominium moving from the centre to periphery the fluid pressure builds up due to centrifugal forces
just like in centrifugal pumps. This phenomenon is substantial in lubrication problems because of the high speed
rotating bodies and for the fact that the flow is distributed from the centre of the shaft to the outer components
through radial pipes.

𝑅22 − 𝑅12 (4)

∆𝑝 = 𝜌 ∙ 𝜔2 ∙
2

For the sake of completeness the Coriolis Forces also would have to be considered but it was verified that their
influence is quite insignificant for this environment.

6 Results

6.1 Flow Characteristics

A qualitative analysis can be carried out by examination of software graphical representation the results. Some
sample Graphic Results are shown in figure 5 and 6.

In figure 5 a pressure contour plot of case 1 rotational condition, 90°C temperature and 4 bar pressure drop is
shown. The figure represents a typical turbulent contour plot characterized by high local pressure drops and very
low distributed friction losses, In fact while on straight connections the contour colour remains constant, high
pressure gradient (then colour gradient) can be observed across disturbances. It is easy to verify that the most
important local friction losses are on inlet restriction and on entrance of radial pipes.

Figure 5: 3D Model of a Roto-Translating Spool Valve

Figure 6 represents a streamline plot of velocity for the same operating condition (rotating case 1, 90 °C, 4 bar
pressure drop). The streamline represent the particles flow path, in this case a helix trajectory is shown: the
rotating shafts produce the circular movement while axial movement is consequence of pressure differentials.
 The 9th International Fluid Power Conference, 9. IFK, March 24-26, 2014, Aachen, Germany

Being the center canal flow rate decreasing from inlet to farther outlets in reason of flow spilled by the radial
outlets, the axial velocity component decreases while angular velocity remains constant. In reason of the above
mentioned velocity pattern the pitch of helix, depending from the axial-angular velocity ratio, decreases
progressively moving from the inlet to the end of the shafts.

The color of the streamlines represent the magnitude of flow velocity, in the radial pipes velocity and flow rate
are proportional, giving a direct information on flow distribution, on the contrary on central canal the
relationship between velocity and flow rate isn’t linear because velocity vectors aren’t parallel to shaft axis.

Figure 6: 3D Model of a Roto-Translating Spool Valve

6.2 Aggregate Data and Analysis

The CFD results were used to build a quite complete map of the flow distribution to the hydraulic consumers.
With this large amount of data it will be possible to estimate the results even in an operating condition not
directly analyzed by interpolation.

Every lubricated component has in a particular operating condition an optimal target flow. If the effective flow is
greater than the target then an excessive power loss will occur, if the effective flow is less than the target then
the lifetime of component will be shortened or in the worst case scenario a fault of component will occur.
Moreover the mapping is useful also to assess the performance of lubrication system identifying the most critical
operating conditions.

In table 3 some sample of results are displayed. The contiguous and same rotating speed outlets were aggregated
to have easier representation of results. This representation is quite effective in fact it was noted that aggregated
outlets to total ratio is quite variable but the ratio of outlet to outlet belonging to the same aggregated set doesn’t
show great variability, this gives the great advantage in analysis phase allowing to concentrate on few sets
instead of many single elements.
 The 9th International Fluid Power Conference, 9. IFK, March 24-26, 2014, Aachen, Germany

Outlet 1 and 2 being the furthermost are placed at the end of the shaft and corresponds to the first set, the second
unity set is formed by the Outlet 2 connected to bearings on the carter , Third set correspond to Outlets placed on
Satellite Carrier, The Fourth coincide to the outlet nearer to Inlet and directly placed on Solar shaft.

To have better understanding the physical behavior of the system the data was aggregated also by operative
condition enlightening how the parameters influence the results.

0°C, 60°C, 90°C,

4 bar pressure drop 4 bar pressure drop 4 bar pressure drop
Outlet
Flow Distribution % Flow Distribution % Flow Distribution %
Position
1 0.06 0.24 0.26
2 0.06 0.23 0.25
3 0.26 1.43 1.68
4 1.54 5.18 5.75
5 1.49 5.17 5.72
6 1.65 5.39 6.11
7 1.75 5.44 6.11
8 1.99 5.57 6.11
9 2.02 5.45 6.04
10 2.78 5.82 6.06
11 2.99 5.78 5.98
12 9.54 8.48 8.09
13 9.87 8.57 8.19
14 6.50 4.79 4.46
15 6.60 4.75 4.42
16 7.81 4.82 4.41
17 8.25 4.85 4.43
18 17.67 9.00 7.87
19 17.17 9.06 8.05
Aggregated Data
Futhermost 0.12 0.47 0.51
Carter 0.26 1.43 1.68
Carrier 16.21 43.79 47.89
Solar 83.42 54.30 49.92

Table 3: Sample Results and Aggregated Results

In figure 7 some significant results at 90°C Fluid Temperature are displayed. Figure 7, left side shows how the
total flow rate changes in reason of pressure drop and operative rotating condition. The curves are parametrized
so that Total Flow Rates are made relative to Flow Rate in Stationary case at 90°C and 4 bar pressure drop.

A very important achievement is that the curves almost perfectly fit to quadratic curves (Coefficient of
Determination 0.99) though this model can be substituted in the global lubrication model by a turbulent
equivalent orifice. This kind of Model Identification (that has to be applied also to other lubrication circuit parts)
gives opportunity to study the complete system distribution, that otherwise would be impossible to be simulated
by CFD in its entirety for the huge size of fluid domain.

Another remark is about the influence on total flow rate and flow distribution of rotating operative condition at
different pressure drops. At fixed total pressure drop the higher flow rate is obtained for stationary case, in fact
the centrifugal force (summing to friction losses) doesn’t increase the total pressure drop (that’s a fixed boundary
condition) but decreases the available pressure drop in radial rotating pipes.
 The 9th International Fluid Power Conference, 9. IFK, March 24-26, 2014, Aachen, Germany

The outcome is that the less is the total pressure drop the most the distribution is in favour of solar outlets, the
more the total pressure drop increase the less centrifugal effect weights on pressure balance, so that at high
pressure drops the curves tend to stationary case.

In figure 8 the same analysis is carried out for 0°C operative condition. Figure 8, left side shows the curves of
total flow rates at various rotating cases scaled to Total Stationary Flow Rate at 90°C and 4 bar pressure drop.
The curves are almost linear and they represent a typical Laminar Flow (that can be described by a simple
concentrated parameters model to be integrated in a global one). It is worthy of attention that the total flow rate
deeply decreases so that the maximum flow rate achievable at maximum considered pressure drop is less than
16% than 90°C cases.

Focusing on figure 8, right side it is possible to appreciate that the laminar flow path is in favour of solar outlets
(that are the nearest ones) so that only less 20% goes to carrier outlets. It was verified that in this condition the
system isn’t able to lubricate satisfactory the end part of the shaft. An interesting remark is that in this case the
distribution isn’t much influenced by the total pressure drop so the ratios showsless variation in reason of
pressure condition.

Figure 7: 3D Model of a Roto-Translating Spool Valve

Figure 8: 3D Model of a Roto-Translating Spool Valve

7 Summary and Conclusion

A CFD Method for Lubrication Circuits has been presented. The Method is able to map the behavior of
Lubrication Circuits, this gives opportunity to assess the performance of lubrication, identifying the critical
operating conditions and improve design process through virtual optimization. Assuring the correct lubrication
 The 9th International Fluid Power Conference, 9. IFK, March 24-26, 2014, Aachen, Germany

distribution improves energy management, increases machine and components reliability and lifetime reducing
the failures.

The main physical phenomena involved were described, moreover an aggregated data analysis was carried out to
manage the vast data collected and to illustrate the various trends and dependency from operative conditions.

Going into details the centrifugal effect is important at low pressure drops and tend to be in favor of outlets
nearest to inlet; at high pressure drops and medium and high temperature the flow balance is satisfactory; at low
temperatures a laminar behavior is shown, the total flow rate falls dramatically and moreover the flow path isn’t
able to lubricate the end part of the shaft.

The method has shown the capability to describe the global system behavior through simple models opening the
possibility to deal with a complete lubrication system analyzing the various parts and building a concentrated
parameters global model. This is an important achievement since it is nowadays impossible to study a modern
off road machine lubrication system in his entirety for the extreme complexity and extent of fluid domain.

This results encourage the development of CFD simulation in the field of Transmission Lubrication as an
integrated part of machine development giving opportunity to optimize and speed up the design process.

Nomenclature

Variable Description Unit

∆p Pressure Differential [Pa]

𝑤 Fluid Velocity [m/s]

𝜇 Fluid Cinematic Viscosity [Pa·s]

R Radius of Pipe [m]

𝐷 Diameter of Pipe [m]

𝐿 Length of Pipe [m]

𝜌 Fluid Density [kg/m3]

𝑅𝑅 Reynolds Number [-]

𝛽 Friction Factor [-]

𝑅2 Outer Radius of Rotating Dominium [m]

𝑅1 Inner Radius of Rotating Dominium [m]

𝜔 Angular Velocity [rad/s]

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