A computational methodology is proposed for prediction of power losses due to pocketing (pumping or squeezing) of oil at the mesh interface of spiral bevel gears. The model employs an existing cutting simulation procedure to define surface geometries of the gears through face-milling and face-hobbing processes. A novel hypoidal discretization method is proposed to define pocket volumes between meshing gear teeth along circumferential and face width directions. An existing fluid mechanics formulation, utilizing principles of conservation of mass, momentum and energy, is used to compute the load-independent (spin) power losses due to pocketing of the medium in the gear mesh interface. A simulation of aerospace applications is presented to highlight the effects of lubrication conditions, on pocketing power losses.

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