Hydraulic machines are faced with increasingly severe performance requirements. The need to design smaller and more powerful machines rotating at higher speeds in order to provide increasing efficiencies has to face a major limitation: cavitation. The problem is inherently three-dimensional, due to the axial clearances, the relief and circumferential grooves, and to the circular pipes through which the fluid enters and exits the pump. A simplified two-dimensional numerical approach by means of computational fluid dynamics (CFD) has been developed for studying the effect of cavitation in the volumetric efficiency of external gear pumps. The assumptions employed prevent from predicting realistic values of the volumetric efficiency, but show to be valid to understand the complex flow patterns that take place inside the pump and to study the influence of cavitation on volumetric efficiency. A method for simulating the contact between solid boundaries by imposing changes in viscosity has been developed. Experiments of unsteady cavitation in water and oil performed by other authors have been numerically reproduced using different cavitation models in order to select the most appropriate one and to adjust its parameters. The influence of the rotational speed of the pump has been analyzed. Cavitation in the suction chamber very effectively damps the water hammer associated to the sudden change of the contact point position at the end of the gearing cycle. At high rotational speeds, the volume of air becomes more stable, reducing the flow irregularity. When cavitation takes place at the meshing region downstream from the contact point, the volume of air that appears acts as a virtual second contact point, increasing the volumetric efficiency of the pump.

Over the years, numerous investigations have established the gerotor fundamentals. This work aims to provide a complete review of the literature from the last decade, focusing on the articles published in the past five years on gerotor technology in hydraulic machines. The report gives a catalogue of guidelines based on the trochoidal-envelope definition, a background analysis, the worldwide distribution of articles in each continent and country and the most frequently used keywords in the field. The paper identifies state-of-the-art research, and reports on current mainstream ideas. From the historical background, this literature review reports the current approaches in gerotor pumps (geometry and performance approaches, modeling and numerical simulations), orbital motors and new concepts. The report will serve as a guide and a directory for novel engineers working with gerotor technology in hydraulic machines. Another intention of this paper is to disseminate the works of the researchers who use this technology around the world, and to provide a scenario for future international collaboration. The paper gives an account of the disparity between academia and engineering applications. There is currently very little published literature on design and production methodologies for gerotor pumps and orbital motors. Hence, the future goal is to collect recommendations that combine academia and industry expertise to make better use of these extensive studies in the field.

Recently several works have been published on numerical simulation of an external gear pump (EGP). Such kinds of pumps are simple and relatively inexpensive, and are frequently used in fluid power applications, such as fluid power in aeronautical, mechanical, and civil engineering. Nevertheless, considerable effort is being undertaken to improve efficiency and reduce noise and vibration produced by the flow and pressure pulsations. Numerical simulation of an EGP is not straightforward principally for two main reasons. First, the gearing mechanism between gears makes it difficult to handle a dynamic mesh without a considerable deterioration of mesh quality. Second, the dynamic metal–metal contact simulation is important when high pressure outflow has to be reproduced. The numerical studies published so far are based on a two-dimensional (2D) approximation. The aim of the present work is to contribute to the understanding of the fluid flow inside an EGP by means of a complete three-dimensional (3D) parallel simulation on a cluster. The 3D flow is simulated in a linux cluster with a solver developed with the openfoam Toolbox. The hexahedral mesh quality is maintained by periodically replacing the mesh and interpolating the physical magnitudes fields. The meshing contact point is simulated with the viscous wall approach, using a viscosity model based on wall proximity. The results for the flow rate ripples show a similar behavior to that obtained with 2D simulations. However, the flow presents important differences inside the suction and the discharge chambers, principally in the regions of the pipes' connection. Moreover, the decompression slot below the gearing zone, which can not be simulated with a 2D approximation, enables a more realistic simulation of a contact ratio greater than 1. The results are compared with experimental measurements recently published.

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.

The aerodynamic complexity of the underbody surfaces of conventional road vehicles is a matter of fact. Currently available literature is focused mainly on very simple Ahmed-body geometries as opposed to realistic car shapes, due to their complexity and computational cost. We attempted to understand the flow behaviour around different realistic conventional road car geometries, and we provide an extensive evaluation of the aerodynamic loads generated. The key findings of this article could potentially set a precedent and be useful within the automotive industry’s investigations on drag-reduction mechanisms or sources of downforce generation. The novelty of the work resides in the realistic approach employed for the geometries and in the investigation of barely researched aerodynamic elements, such as front diffusers, which might pave the way for further research studies. A baseline flat-underfloor design, a 7${}^{\circ }$ venturi diffuser-equipped setup, a venturi diffuser with diagonal skirts, and the same venturi diffuser with frontal slot-diffusers are the main configurations we studied. The numerical predictions evaluated using RANS computational fluid dynamics (CFD) simulations deal with the aerodynamic coefficients. The configuration that produced the highest downforce coefficient was the one composed of the 7${}^{\circ }$ venturi diffuser equipped with diagonal sealing skirts, achieving a $C_L$ value of −0.887, which represents an increase of around 1780% with regard to the baseline model. That achievement and the gains in higher vertical loads also entail a compromise with an increase in the overall air resistance. The performance achieved with diffusers in the generation of downforce is, as opposed to the one obtained with conventional wings, a cleaner alternative, by avoiding wake disturbances and downwash phenomena.

The high complexity of current Formula One aerodynamics has raised the question of whether an urgent modification in the existing aerodynamic package is required. The present study is based on the evaluation and quantification of the aerodynamic performance on a 2017 spec. adapted Formula 1 car (the latest major aerodynamic update) by means of Computational Fluid Dynamics (CFD) analysis in order to argue whether the 2022 changes in the regulations are justified in terms of aerodynamic necessities. Both free stream and flow disturbance (wake effects) conditions are evaluated in order to study and quantify the effects that the wake may cause on the latter case. The problem is solved by performing different CFD simulations using the OpenFoam solver. The significance and originality of the research may dictate the guidelines towards an overall improvement of the category and it may set a precedent on how to model racing car aerodynamics. The studied behaviour suggests that modern F1 cars are designed and well optimised to run under free stream flows, but they experience drastic aerodynamic losses (ranging from −23% to 62% in downforce coefficients) when running under wake flows. Although the overall aerodynamic loads are reduced, there is a fuel efficiency improvement as the power that is required to overcome the drag is smaller. The modern performance of Ground Effect by means of vortices management represent a very unique and complex way of modelling modern aerodynamics, but at the same time notably compromises the performance of the cars when an overtaking maneuver is intended.