Influence of the interteeth clearances on the flow ripple in a gerotor pump for engine lubrication

A gerotor pump, which is widely used in the automotive industry for engine oil lubrication, produces an instantaneous flow fluctuation and the estimation of this is fundamental in order to evaluate the pump quality for silent and smooth operation. The intricate aspects of the pumping process of a gerotor pump make computational fluid dynamics the appropriate tool for modelling and simulation to provide insights into its flow characteristics. Because the instantaneous flow is rather dependent on the teeth contact, a new boundary condition of a virtual wall was developed, which allows simulation of the teeth contact in the interteeth radial clearances. This new boundary condition is utilized in a three-dimensional model of the gerotor pump with mesh deformation and remeshing at every time step by means of a home-made ad-hoc code programmed by the present authors and named viscous wall cell. The code has been integrated into the computational fluid dynamics solver. The interteeth clearances are studied under the following different operating conditions (working pressures and rotational velocities): first, no contact points (no teeth contact is studied in order to prove that, even if the interteeth radial clearance is sufficiently small, the leakage cannot be negligible); second, all contact points (the ideal approach is considered with zero interteeth radial clearances used to model zero manufacturing tolerances); third, one contact point at different locations (the existence of manufacturing tolerances and the teeth contact approach make the pump's operation and its pumping mechanism more realistic in the simulation). The numerical instantaneous flow is compared with the analytical instantaneous flow, with the instantaneous flow modelled by using the bond graph technique, and with the experimental determination of the flow ripple for a specific unit. The results obtained show the importance of simulating the teeth contact and prove to be an excellent estimation of the instantaneous flow behaviour to obtain the dynamic properties of a gerotor pump under more realistic conditions than its design.