Helical Gear Pump: A Comparison between a Lumped Parameter and a Computational Fluid Dynamics-Based Approaches

This research presents a comparison between two numerical approaches developed and later compared for studying External Gear Pumps (EGPs). Models have been developed for studying pumps with helical gears. Firstly, a three-dimensional (3D) CFD numerical model has been built using a commercial code. Then, a new tool called EgeMATor MP+, completely developed by the authors and capable of completely simulating this pump's typologies is presented. Thanks to different subroutines developed in different interconnected environments, this tool can fully analyze those pumps, starting from the drawing. Both numerical approaches have been detailed, highlighting their strengths and weaknesses and the tweaking required to reach more accurate results. Both numerical models have been set up with the same boundary conditions to obtain a more accurate comparison. Comparisons have been performed using tests performed on a commercial pump taken as reference, focusing on steady-state volumetric performance as well as the transient features of the outlet port pressure oscillations. The comparison of the (Q,p) characteristics showed that the 3D CFD numerical model has a slightly better accuracy, but both models have errors that fall into the uncertainty range of the experimental measurements. In addition, the pressure ripples comparison verified good agreements, where also the double flank behavior of the pump is predicted. While comparing the two simulation approaches, the paper highlights the limits and strengths of each one of the two approaches. In particular, it is shown how both models can match the experimental results considering proper assumptions. The paper constitutes a unique contribution to the field of numerical simulation of EGPs and represents a useful reference to designers looking for suitable methods for simulating existing or novel design solutions.