Engineering topics

Handschuh, Robert

Publications and source records attributed to Handschuh, Robert.

7 records

NASA NTRS2018

Evaluation of a Variable Thickness Hybrid Composite Bull Gear

For several years, NASA Glenn Research Center and the U.S. Army Research Laboratory have been investigating hybrid (compositesteel) gear technology for use in vertical lift drive systems. The hybrid gear concept replaces the structural portion of a gear between the shaft and the gear rim with a lightweight carbon fiber composite, in an effort to reduce the overall weight of a gear and increase the drive system power density. An overview of the concept of the hybrid gear design is described in Ref. 1, 2, and 3. The research presented in these references includes both small-scale and large-scale hybrid gear concepts all of which have a constant composite thickness throughout. The design described in this paper is of a variable thickness, such that the composite is thickest at the inner diameter and this thickness is gradually reduced toward the outer diameter. The resulting stair stepped design stems from dropping plies of the braided carbon fiber composite fabric gradually with increased radius. Additionally, the interlock pattern at the inner metallic adapter was adjusted slightly from previous designs to obtain a better stress distribution on the inner metallic adapter. The manufactured variable thickness web was tested both in static torsion tests and operationally in a relevant gearbox environment. The results of these experiments will be presented and compared to a baseline steel configuration.

Rotorcraft Propulsion↗

NASA NTRS2016

Performance Investigation of a Full-Scale Hybrid Composite Bull Gear

Hybrid composite gears have been investigated as a weight saving technology for rotorcraft transmissions. These gears differ from conventional steel gears in that the structural material between the shaft interface and the gear rim is replaced with a lightweight carbon fiber composite. The work discussed here is an extension of previous coupon level hybrid gear tests to a full-scale bull gear. The NASA Glenn Research Center High-Speed Helical Gear Rig was modified for this program allowing several hybrid gear web configurations to be tested while utilizing the same gear rim. Testing was performed on both a baseline (steel) web configuration and a hybrid (steel-composite)configuration. Vibration, orbit and temperature data were recorded and compared between configurations. Vibration levels did not differ greatly between the hybrid and steel configurations, nor did temperature differential between inlet and outlet. While orbit shape displayed differences between the hybrid and baseline configurations, the general overall amplitude was comparable. The hybrid configuration discussed here successfully ran at 3300 hp(2,460 kW), however, progressive growth of the orbit while running at this test condition discontinued the test. Researchers continue to search for the cause of this orbit shift.

Transmissions↗

NASA NTRS2009

CFD Technology for Rotorcraft Gearbox Windage Aerodynamics Simulation

A computational fluid dynamics (CFD) method is adapted, validated and applied to spinning gear systems with emphasis on predicting windage losses. Several spur gears and a disc are studied. The CFD simulations return good agreement with measured windage power loss. Turbulence modeling choices, the relative importance of viscous and pressure torques with gear speed and the physics of the complex 3-D unsteady flow field in the vicinity of the gear teeth are studied.

Handschuh, Robert↗

NASA NTRS2007

Wear of Spur Gears Having a Dithering Motion and Lubricated with a Perfluorinated Polyether Grease

Gear contact surface wear is one of the important failure modes for gear systems. Dedicated experiments are required to enable precise evaluations of gear wear for a particular application. The application of interest for this study required evaluation of wear of gears lubricated with a grade 2 perfluorinated polyether grease and having a dithering (rotation reversal) motion. Experiments were conducted using spur gears made from AISI 9310 steel. Wear was measured using a profilometer at test intervals encompassing 10,000 to 80,000 cycles of dithering motion. The test load level was 1.1 GPa maximum Hertz contact stress at the pitch-line. The trend of total wear as a function of test cycles was linear, and the wear depth rate was approximately 1.2 nm maximum wear depth per gear dithering cycle. The observed wear rate was about 600 times greater than the wear rate for the same gears operated at high speed and lubricated with oil.

Krantz, Timothy↗

NASA NTRS2004

New Design and Improvement of Planetary Gear Trains

The development of new types of planetary and planetary face-gear drives is proposed. The new designs are based on regulating backlash between the gears and modifying the tooth surfaces to improve the design. The goal of this work is to obtain a nearly uniform distribution of load between the planet gears. In addition, a new type of planetary face-gear drive was developed in this project.

Handschuh, Robert↗

NASA NTRS2003

Modified Involute Helical Gears: Computerized Design, Simulation of Meshing, and Stress Analysis

The computerized design, methods for generation, simulation of meshing, and enhanced stress analysis of modified involute helical gears is presented. The approaches proposed for modification of conventional involute helical gears are based on conjugation of double-crowned pinion with a conventional helical involute gear. Double-crowning of the pinion means deviation of cross-profile from an involute one and deviation in longitudinal direction from a helicoid surface. Using the method developed, the pinion-gear tooth surfaces are in point-contact, the bearing contact is localized and oriented longitudinally, and edge contact is avoided. Also, the influence of errors of aligment on the shift of bearing contact, vibration, and noise are reduced substantially. The theory developed is illustrated with numerical examples that confirm the advantages of the gear drives of the modified geometry in comparison with conventional helical involute gears.

Handschuh, Robert↗

NASA NTRS1996

Meshing of a Spiral Bevel Gearset with 3D Finite Element Analysis

Recent advances in spiral bevel gear geometry and finite element technology make it practical to conduct a structural analysis and analytically roll the gearset through mesh. With the advent of user specific programming linked to 3D solid modelers and mesh generators, model generation has become greatly automated. Contact algorithms available in general purpose finite element codes eliminate the need for the use and alignment of gap elements. Once the gearset is placed in mesh, user subroutines attached to the FE code easily roll the gearset through mesh. The method is described in detail. Preliminary results for a gearset segment showing the progression of the contact lineload is given as the gears roll through mesh.

Bibel, George D.↗