Proceedings of ASME Turbo Expo 2020
Turbomachinery Technical Conference and Exposition
Investigating Effects of the Two-Phase Media on the Windage Power Losses of a Spur Gear
with Shrouding Configurations
Ali Kıvanç Ersan1, Mehmet Ali Yavuz1, Murat Kadri Aktaş2
1Turkish Aerospace, Ankara, Turkey
2TOBB University of Economics and Technology, Ankara, Turkey
ABSTRACT
Significant power losses are encountered in gearboxes
due to windage effects; these losses can consume up to 3%
of the transmitted power in gearboxes. Windage power
losses have more importance at gears, which have higher
rotational speed; because these losses increase
proportionally with rotating speed. Pollutant emission and
fuel consumption are reduced by this advantage and also
energy is saved.
INTRODUCTION
Gears and gearboxes are used for transmitting the power
between the shafts in transmission systems. To get the best
efficiency at the gearboxes, windage power losses are not
negligible. These losses can reach up to 1 MW in rotary and
vertical take-off and landing system at high rotational
speeds. [1] Another study in literature said that, windage
power losses are generated from the friction, make up 10%
of the total power losses. [2]
In general, using shrouding and lubrication are the most
effective ways in transmission system industry for reducing
the windage power losses. There are many numerical and
experimental studies. First studies were focused on single
phase (air) media. On the other hand, Anderson and
Loewenthal were studied for two-phase (air-oil) and they
suggested an analytical formula for calculating the
predicted power loss. [3] Seetharaman and Kahraman
suggested a fluid mechanics model, which calculates the
predicted spin power losses in two-phase (air-oil) media. [4]
1
GT2020
June 22-26, 2020, London, England
GT2020-14864
In general, using shroud is limited the fluid flow around
the gear for reducing windage power losses for varying
shrouding length and rotational speed. Also, effects of the
single-phase media and two-phase media is investigated.
CFD++ commercial software is used for numerical
simulations.
Keywords: windage, gearbox, efficiency
Simmons et al. used experiments for showing the effects of
shrouding and oil on the windage power losses for a bevel
gear. [5] Kunz et al. suggested a computational fluid
dynamics methodology for the analysis of both single-phase
and two-phase media. [6] Arisawa et al. was using a
numerical approach for two-phase media, a significant
reduction on windage and churning losses with using
shrouding was showed. [7] Al et al. presented an Eulerian
multiphase model for the two-phase flow and for spiral
bevel gear. [8]
In this paper, the windage power losses in two-phase media
for a spur gear have been investigated with a numerical
approach. The purpose of this study to show the effects of
the two-phase media on the windage power losses. Also,
effects of the shrouding length and rotational speed were
investigated. In addition to some old studies which were
already published [9] new studies are included in this paper
for showing the investigated effects.
MODEL AND METHODOLOGY equation set were solved for the two-phase problem.
Applied equation set is given below. [11]
Model
𝜕(𝜌𝑢̅𝑖 )
A spur gear geometry, which has already had numerical and =0 (1)
𝜕𝑥𝑖
experimental data, was chosen from the published study.
𝜕 𝜕𝑝̅ 𝜕 𝜕𝑢̅𝑖 𝜕𝑢̅𝑗
Properties of the selected gear are given in Table 1. [10] ̅̅̅̅̅
(𝜌𝑢 ̅̅̅̅̅̅
′ ′
𝑖 𝑢𝑗 + 𝜌𝑢𝑖 𝑢𝑗 ) = − + [𝜇 ( + )] (2)
𝜕𝑥𝑗 𝜕𝑢̅𝑖 𝜕𝑥𝑗 𝜕𝑥𝑗 𝜕𝑥𝑖
Table 1: Properties of the Selected Spur Gear 𝜕 𝜕 𝜕 𝜇𝑡 𝜕𝑘
(𝜌𝑘) + (𝜌𝑘𝑢𝑖 ) = [(𝜇 + ) ] + 𝑃𝑘 − 𝛽 ′ 𝜌𝑘𝜔 (3)
𝜕𝑡 𝜕𝑥𝑖 𝜕𝑥𝑗 𝜎𝑘 𝜕𝑥𝑗
Pitch Diameter Tooth Width Number
Module 𝜕 𝜕 𝜕 𝜇𝑡 𝜕𝜔 𝜔
(mm) (mm) of Teeth (𝜌𝜔) + (𝜌𝜔𝑢𝑖 ) = [(𝜇 + ) ] + 𝛼 𝑃𝑘 − 𝛽𝜌𝜔2 (4)
288 30 4 72 𝜕𝑡 𝜕𝑥𝑖 𝜕𝑥𝑗 𝜎𝜔 𝜕𝑥𝑗 𝑘
𝑘
With using AutoCAD commercial software and using the 𝜇𝑡 = 𝜌 (𝑆𝑆𝑇 𝑚𝑜𝑑𝑒) (5)
𝜔
parameters which is given above, spur gear geometry was
created. This geometry is given in Figure 1. 𝑃 = 𝜌𝑅𝑇 (6)

In equations, are given above, ρ denotes fluid density, u

denotes velocity component, xi denotes Cartesian
coordinate, μ denotes dynamic viscosity, 𝜌𝑢 𝑖 𝑢𝑗 denotes
̅̅̅̅̅
Reynolds stress, μt denotes eddy viscosity, δij denotes
Kronecker’s Symbol, k denotes turbulent kinetic energy, ω
denotes specific dissipation rate, Pk denotes turbulence
production, Re denotes Reynolds Number, 𝜏𝑢𝑖 denotes
interphase drag.
In Equation 7 and Equation 8, continuity and conservation
of the momentum equations are given. [11]

Figure 1: Created Spur Gear Geometry 𝜕(𝜌𝑝𝑖 ⃗⃗⃗⃗⃗

𝑢𝑝𝑖 )
= 0 (7)
𝜕𝑥𝑖
To investigate the effect of the shrouding length, several
shrouding configurations are applied. These configurations 𝜕(𝜌𝑝𝑖 ⃗⃗⃗⃗⃗
𝑢𝑝𝑖 )
are given in Table 2. As shown in this configurations, axial + 𝛻 ∙ (𝜌𝑝𝑖 ⃗⃗⃗⃗⃗ 𝑢𝑝𝑖 ) = ⃗⃗⃗⃗⃗
𝑢𝑝𝑖 ⃗⃗⃗⃗⃗ 𝐹𝐷𝑖 (8)
𝜕𝑡
shrouding was assumed as a constant 0.6 mm and radial
shrouding was varied from 3.6 mm to 14.4 mm. Although there are lots of loss source in momentum
Table 2: Applied Shrouding Configurations
conservation equation, only drag between the two phases
has been taken into account and the other loss sources were
Axial Shrouding Radial Shrouding assumed as negligible. Calculation of these losses is given
(mm) (mm) in Equation 9, Equation 10 and Equation 11. [11]
I 0.6 3.6
II 0.6 7.2 1.0 + 0.15 (𝑅𝑒𝑖 )0.687 , 𝑅𝑒𝑖 < 1000
𝑓𝐷𝑖 = { (9)
0.01833 𝑅𝑒𝑖 , 𝑅𝑒𝑖 > 1000
III 0.6 10.8
IV 0.6 14.4 𝜌𝑓 |𝑢
⃗⃗⃗⃗𝑓 − ⃗⃗⃗⃗⃗
𝑢𝑝𝑖 |𝑑𝑖
𝑅𝑒𝑖 = (10)
𝜇𝑓
The effect of the rotating speed on the windage power losses
is also investigated. For each shrouding length 2
𝜌̃𝑝𝑖 𝑑𝑖
configuration, simulations are carried out for rotational 𝜏𝑢𝑖 = (11)
18𝜇𝑓
speeds of 400 rad/s, 500 rad/s, 600 rad/s and 700 rad/s.
The effect of the two-phase media on the windage power Only one tooth was modeled to reduce the calculation cost
losses is also investigated. Two-phase media and single- of the simulations and made the simulations in the tooth
phase media were used only for shrouding configuration IV space more detailed. Periodic boundary conditions are used
at all rotational speeds. at the enter and exit section of the tooth. These sections are
shown in Figure 2 and Figure 3.
Methodology
Turbulent flow occurs between the fluent and gear surface
at these rotational speed values. Therefore, Reynolds
Averaged Navier-Stokes (RANS) equations in three-
dimensional Cartesian coordinate system along with k-ω
(SST) turbulence model are employed as the governing
equations. Although incompressible form of the selected
model and equation set were solved for the single-phase
problem, compressible form of the selected model and

2
 Figure 2: Periodic Boundary Conditions of the Gear
Figure 4: Boundary Conditions at the Gear Surface

Figure 3: Periodic Boundary Conditions of the Gear

For all gear surfaces, shown in Figure 4 and Figure 5, no-
slip boundary conditions were applied.

Figure 5: Boundary Conditions at the Gear Surface

3
Shroud walls, shown in Figure 6 and Figure 7, were defined
as rotating at z-axis with zero velocity.

Figure 8: Sample Grid

Structured hexahedral mesh type was used to generate the
grid. Generated cell numbers for all shrouding
configurations are given in Table 3.
Table 3: Cell Numbers of the Shrouding Configurations
Axial Radial
Cell
Shrouding Shrouding
Number
(mm) (mm)
I 0.6 3.6 934902
II 0.6 7.2 984192
Figure 6: Boundary Conditions at the Axial Shrouding III 0.6 10.8 1023624
IV 0.6 14.4 1043340
A wall function provided by CFD++ was adopted for wall
treatment. This wall function can be used when y +<300.
[11] y+<40 was satisfied in two-phase media simulations.
Formula of y+ is given Equation 12.
𝜌𝑦𝑢𝜏
𝑦+ = (12)
𝜇

Inlet and outlet channels for the model at the lower end of
each side of axial shroud are introduced as suggested in a
study. [6] These inlet and outlet channels are shown in
Figure 9.

Figure 7: Boundary Conditions at the Radial Shrouding

Mesh structure was generated with using Pointwise
commercial software. The sample mesh grid of the gear
model with shrouding is given in Figure 8.
Figure 9: Oil Inlet and Outlet Channels
4
Oil particles were assumed as spherical in Eulerian
Dispersed Phase (EDP) model in simulations. Rosin-
Rammler distribution functions are used for assigning the
particle diameters and their distributions. [10] These
functions are given in Equation 13 and Equation 14.
𝑥 𝑛
−(𝑥 )
𝑌 =1−𝑒 0 (13)
𝜎 0.5
𝑥0 = 3.8 ( ) (14)
𝜌∗𝐷∗𝜔 2
In equations, which are given above, 𝜎 denotes surface
tension, 𝜌 denotes effective density, 𝐷 denotes gear
diameter, 𝜔 denotes rotation speed. Five different particle
diameters were defined in simulations. An example of the
oil particles distribution is given in Figure 10.
simulations to make the flow more realistic. Oil enters into
the tooth space from inlet channel with a small velocity and
exits from the outlet channel. For all shrouding length and
rotation speed configurations, inlet oil volume fraction is
defined as 0.03 in simulation setup.
Shrouding Configuration Case I
In this case, axial shrouding is 0.6 mm and radial shrouding
is 3.6 mm. Convergence of this case take lesser time than
the other cases due to smaller shrouding length. It is
observed that 15000-20000 steps were enough for
convergence. Oil distribution for YZ plane is given in
Figure 11.

Figure 11: Oil Distribution for Case I (YZ Plane)

@600 rad/s
Contour levels represent continuous phase (air) volume
Figure 10: Oil Particles Distribution by Diameter for 600 rad/s
fraction. Although some of oil particles are dispersed out of
Rotation Speed
the tooth space and bunch near to the shrouding walls by
centrifugal forces generated by the rotation, the rest of the
Steady state flow fields were selected in simulations. In
oil particles follow vortex pattern at the tooth space. For XY
addition, the simulations continued until the convergence
plane oil distribution is given in Figure 12.
order reached 10-5.

Validation

In order to ensure the reliability of the applied numerical

model, it was necessary to validate this model with a study
that already has results in literature. For this validation a
study was selected, that one published in 2012. [6] There
are results for 600 rad/s, 700 rad/s and 800 rad/s rotational
speed and for 2 μm – 16 μm oil particle diameters. The
results are found similar with literature data. These results
are given in Table 4.

Table 4: Results of the Literature and Simulations

Figure 12: Oil Distribution for Case I (XY Plane)

RESULTS
Particle diameters were defined in EDP Model info set of
the CFD++ Setup Tool. Rosin-Rammler distribution
function is adopted for obtaining oil particle diameter
distribution. Five different particle diameters were used in
@600 rad/s
As mentioned before vortex pattern can be easily seen in
XY plane. Not negligible amount of oil volume is gathered
near to the wall region and this oil volume called thin oil
film. Thin oil film is important to lubrication of the contact
surfaces. Because of the oil film, viscous losses are
increasing at this surface.

5
Distribution of each oil particles which have different
diameter are given in Figure 13, Figure 14, Figure 15,
Figure 16 and Figure 17. Particles with smaller diameter
distribute throughout the tooth space. On the other hand, the
particles that have bigger diameter bunch near to the
shrouding walls.
Figure 13: Oil Distribution of 2 μm Particle Diameter
(Shrouding Configuration Case I)
Figure 14: Oil Distribution of 4 μm Particle Diameter
(Shrouding Configuration Case I)
Figure 15: Oil Distribution of 6 μm Particle Diameter
(Shrouding Configuration Case I)
Figure 16. Oil Distribution of 8 μm Particle Diameter
(Shrouding Configuration Case I)
6
Figure 17: Oil Distribution of 10 μm Particle Diameter
(Shrouding Configuration Case I)
Pressure distribution at the gear walls at 600 rad/s for
shrouding case I is given in Figure 18. Contour levels show
absolute pressure because compressible RANS equations
are solved for two-phase media. As expected, high pressure
values are seen at the areas on where flow around the gear
first contacts with the gear wall and enters the tooth space.
Pressure values decrease from tooth tip point to tooth root.
Figure 18: Pressure Distribution at Gear Walls (Shrouding
Configuration Case I, @600 rad/s)
As mentioned before, contour levels show base pressure
values. Difference between lowest pressure value and
highest-pressure value increases with rotational speed. The
result is expected. The lowest pressure value is 101600 Pa
and highest-pressure value is 102600 Pa so, the difference
equals to 1000 Pa.
To investigate the rotational speed effect on the windage
power losses for same shrouding configuration case,
analysis is repeated for different rotational speed values.
400rad/s, 500 rad/s and 700 rad/s rotational speed values are
used in analysis. Pressure distribution at gear walls for each
specific rotational speed value, is given in Figure 19, Figure
20 and Figure 21.

Figure 19: Pressure Distribution at Gear Walls (Shrouding
Configuration Case I, @400 rad/s)
Figure 20: Pressure Distribution at Gear Walls (Shrouding
Configuration Case I, @500 rad/s)
Figure 21: Pressure Distribution at Gear Walls (Shrouding
Configuration Case I, @700 rad/s)
The pressure differences for each case are given in Table 5.
7
Table 5: Pressure Differences for Each Rotational Speed Values
Rotational Speed Pressure Difference
(rad/s) (Pa)
400 380
500 800
600 1000
700 1300
As shown in Table 5, pressure difference values increase
with rotational speed values.
Shrouding Configuration Case II
In this configuration case, axial shrouding is 0.6 mm and
radial shrouding is 7.2 mm. It is observed that 20000-30000
steps are enough for convergence. Oil distribution for YZ
plane is given in Figure 22.
Figure 22: Oil Distribution for Case II (YZ Plane)
Although some of oil particles are dispersed out of the tooth
space and bunch near to the shrouding walls by centrifugal
forces generated by the rotation, the rest of the oil particles
follow vortex pattern at the tooth space. For XY plane oil
distribution is given in Figure 23. Vortex pattern and thin
oil film can be easily seen in XY plane.
Figure 23: Oil Distribution for Case II (XY Plane)
Pressure distribution at the gear walls at 600 rad/s for
shrouding case II is given in Figure 24. Contour levels show
absolute pressure values. As expected, high pressure values
are seen at the areas on where flow around the gear first
contacts with the gear wall and enters the tooth space. As
similar to previous case, pressure values decrease from
tooth tip point to tooth root.
 values are seen at the flow and wall contact points also,
pressure values decrease from tooth tip point to tooth root.

Figure 24: Pressure Distribution at Gear Walls (Shrouding

Configuration Case II, @600 rad/s)
Shrouding Configuration Case III

In this configuration case, axial shrouding is 0.6 mm and

radial shrouding is 10.8 mm. It is observed that 40000-
50000 steps are enough for convergence. Oil distribution
for YZ plane is given in Figure 25. Figure 27: Pressure Distribution at Gear Walls (Shrouding
Configuration Case III, @600 rad/s)
Shrouding Configuration Case IV

In this configuration case, axial shrouding is 0.6 mm and

radial shrouding is 14.4 mm. It is observed that 60000-
75000 steps are enough for convergence. Oil distribution
for YZ plane is given in Figure 28.

Figure 25: Oil Distribution for Case III (YZ Plane)

Although some of oil particles are dispersed out of the tooth
space and bunch near to the shrouding walls by centrifugal
forces generated by the rotation, the rest of the oil particles
follow vortex pattern at the tooth space. For XY plane oil
distribution is given in Figure 26. Vortex pattern and thin
oil film can be easily seen in XY plane. Figure 28: Oil Distribution for Case IV (YZ Plane)
Although some of oil particles are dispersed out of the tooth
space and bunch near to the shrouding walls by centrifugal
forces generated by the rotation, the rest of the oil particles
follow vortex pattern at the tooth space. For XY plane oil
distribution is given in Figure 29. Vortex pattern and thin
oil film can be easily seen in XY plane.

Figure 26: Oil Distribution for Case III (XY Plane)

Pressure distribution at the gear walls at 600 rad/s for
shrouding case III is given in Figure 27. Contour levels
show absolute pressure values. As expected, high pressure
8
 Figure 29: Oil Distribution for Case IV (XY Plane)
Pressure distribution at the gear walls at 600 rad/s for
shrouding case IV is given in Figure 30. Contour levels
show absolute pressure values. As expected, high pressure
values are seen at the flow and wall contact points also,
pressure values decrease from tooth tip point to tooth root.
Figure 30: Pressure Distribution at Gear Walls (Shrouding
Configuration Case IV, @600 rad/s)
In Figure 31, calculated power losses values for each
shrouding configuration case are given. As expected, power
losses increase with at higher rotational speed also, power
losses increase with bigger shrouding lengths. These results
show us that main reason of windage power losses is the
amount of fluid affected by the gear. Increasing shrouding
length or rotation speed causes additional flow around the
gear regardless of the operational environment.
9
Figure 31: Power Losses Values
Also, two-phase media effects on the windage power loss
were investigated. Sigle-phase media and two-phase media
solutions were applied only for shrouding configuration IV.
Both power loss results are given in Figure 32.
Figure 32: Power Losses Values
As clearly shown in Figure 32, there is a huge difference
between single-phase results and two-phase results. Power
loss values are increasing with two-phase media.
CONCLUSIONS
In this study, windage power losses of two-phase media for
a spur gear are investigated. For reducing the computational
cost and more detailed analysis, periodic boundary
conditions are employed. Eulerian Dispersed Phase Model
is used for modelling the two-phase media. For determining
the oil particles diameters, Rosin-Rammler distribution
function is used. There are five different particle diameters.
Analysis are repeated for three different shrouding
configurations, which lengths are given above also, analysis
are repeated for four different rotation speed values. As a
result:
• Windage power losses increase with rotational
speed
• Windage power losses increase with two-phase
media
• Windage power losses increase with bigger
shrouding lengths
• Particles which have bigger particle diameter
bunch at near of the shrouding walls
• Pressure difference values increase with rotational
speed
Different shrouding configurations are planned to be
simulate in two-phase media also, another plan is to
investigate the effects of the different gear geometries on
the windage power loss.
ACKNOWLEDGMENTS
The authors gratefully acknowledge the financial support
for this work received from The Rotary Wing Technology
Center, TAI (Turkish Aerospace Industries) under Grant #
DKTM/2015/14
REFERENCES
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[3] Anderson, N. E., and Loewenthal, S. H., 1981,
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Gear System Power Loss,” ASME J. Mech. Des., 103, pp.
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10
[4] Seetharaman, Satya and Ahmet Kahraman. 2010. “A
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