Modelling and Analysis of Hypoid Gear Churning Loss in Rear Drive Axle: The Role of Oil Viscosity and Empirical Parameters

This definitive study investigates the variation of churning losses occurring with hypoid ring and pinion gear sets and puts primary importance to factors that determine energy dissipation in these mechanisms. A detailed investigation shows that viscosity is critical, particularly due to large temperature-dependent variations. Besides this, the study focuses on particular attention to experimental parameters derived from measured data to model churning losses. Churning Loss itself originates in the interaction between the rotation of the gears and the lubricating oil - a source of significant inefficiency within the overall drivetrain. A robust, comprehensive model has been formulated to take this into account. It does not only account for variable oil viscosity with temperature but integrates key empirical parameters that reflect observed behaviours in gear systems. The study adopts a multidimensional approach by considering the influence of various other factors. It investigates how oil density affects hydrodynamic resistance, which is essential for understanding the flow characteristics of the lubricant under various operational conditions. The research also explores the effects of fluid fill levels within the gear housing, analyzing how variations in oil distribution can affect lubrication efficacy and increase or decrease energy losses. It further defines the relationship of oil volume with power losses, signifying its importance in optimizing gear performance. This developed simulation model will thus give a holistic understanding of fluid dynamics relating to energy dissipation within gear systems through analysis of how these variables interact with each other and kinematic viscosity. This level of detail gives a deeper insight into the mechanisms in operation, thereby fostering better methodology in optimising churning losses. The results of this study have important practical implications for optimizing lubrication methodology, refining gear housing designs, and selecting the most appropriate fluids for use in gear systems. Through this study and analysis, the findings will not only add value to what is known in the automotive engineering environment but also open’s diversification to more efficient and eco-friendly drivetrain systems. Tackling real problems in engineering, this study bridges the divide between theoretical models and applications by equipping engineers with more advanced tools to enhance efficiency in overall system performance and efficiency. Keywords: Power loss, Lubricating oil, Viscosity, Temperature, Density, Empirical formulas, Gear System, etc.