Abstract

Designing efficient, grease-lubricated gearboxes—particularly for high-load applications like steering drives—presents unique engineering challenges. SPN Schwaben Präzision, in collaboration with EnginSoft GmbH, uses advanced simulation tools to optimize gearbox lubrication, focusing on lifetime performance and minimal maintenance. Grease offers advantages such as long-term stability and effective adhesion but requires precise control of quantity and targeted distribution to prevent wear or overheating.

To address this, SPN employs Particleworks, a particle-based CFD simulation tool using the MPS method, to model grease as a non-Newtonian fluid and simulate its behavior under operational conditions. This allows engineers to design housing geometries that form grease reservoirs at critical points, such as bearings and gear teeth, even at high speeds.

Physical tests using transparent housings validated the simulation accuracy, confirming its effectiveness in replicating real-world grease behavior. The result is an optimized balance between lubrication, thermal performance, and energy efficiency. This approach leads to more durable, cost-effective gearboxes with reduced energy consumption and enhanced service life.