Engineering topics

Krantz, Timothy L.

Publications and source records attributed to Krantz, Timothy L..

At least 37 records · Page 2

NASA NTRS2005

A Study of Spur Gears Lubricated With Grease-Observations From Seven Experiments

To improve understanding of gears operating with a perfluoro type space-qualified grease, seven spur gear experiments were performed. Test conditions were selected to study the influences of torque, lubricant type, and atmosphere. Two testing torques provided nominal pitch-line Hertz stresses greater and lesser than the contact stress limit as recommended by the grease manufacturer. As was expected, all tests resulted in some gear tooth wear. Discoloration of the perfluoro type grease occurred for all tests. Tests in dry nitrogen produced some dark-grey colored perfluoro type grease. Testing in either ambient or dry air produced red debris after short test duration, and for tests of longer duration large amounts of red debris, red grease, and wear were evident. Tests using higher torques produced more debris. The first indications of discoloration occurred more quickly with higher test torques. Total amounts of wear were quite significant, up to four times the profile tolerance for AGMA Class 10 gears.

Krantz, Timothy L.↗

NASA NTRS2005

Program for Weibull Analysis of Fatigue Data

A Fortran computer program has been written for performing statistical analyses of fatigue-test data that are assumed to be adequately represented by a two-parameter Weibull distribution. This program calculates the following: (1) Maximum-likelihood estimates of the Weibull distribution; (2) Data for contour plots of relative likelihood for two parameters; (3) Data for contour plots of joint confidence regions; (4) Data for the profile likelihood of the Weibull-distribution parameters; (5) Data for the profile likelihood of any percentile of the distribution; and (6) Likelihood-based confidence intervals for parameters and/or percentiles of the distribution. The program can account for tests that are suspended without failure (the statistical term for such suspension of tests is "censoring"). The analytical approach followed in this program for the software is valid for type-I censoring, which is the removal of unfailed units at pre-specified times. Confidence regions and intervals are calculated by use of the likelihood-ratio method.

Krantz, Timothy L.↗

NASA NTRS2005

Spur Gear Wear Investigated in Support of Space Shuttle Return-To-Flight Efforts

As part of NASA s Return-To-Flight efforts, the Space Operations Program investigated the condition of actuators for the orbiter s rudder speed brake. The actuators control the position of the rudder panels located in the tail of the orbiter, providing both steering control and braking during reentry, approach, and landing. Inspections of flight hardware revealed fretting and wear damage to the critical working surfaces of the actuator gears. To best understand the root cause of the observed damage and to help establish an appropriate reuse and maintenance plan for these safety critical parts, researchers completed a set of gear wear experiments at the NASA Glenn Research Center.

Krantz, Timothy L.↗

NASA NTRS2004

Gear Performance Improved by Coating

Gears, bearings, and other mechanical elements transmit loads through contacting surfaces. Even if properly designed, manufactured, installed, and maintained, gears and bearings will eventually fail because of the fatigue of the working surfaces. Economical means for extending the fatigue lives of gears and bearings are highly desired, and coatings offer the opportunity to engineer surfaces to extend the fatigue lives of mechanical components. A tungsten-containing diamondlike-carbon coating exhibiting high hardness, low friction, and good toughness was evaluated for application to spur gears. Fatigue testing was done at the NASA Glenn Research Center on both uncoated and coated spur gears. The results showed that the coating extended the surface fatigue lives of the gears by a factor of about 5 relative to the uncoated gears. For the experiments, a lot of spur test gears made from AISI 9310 gear steel were case-carburized and ground to aerospace specifications. The geometries of the 28-tooth, 8-pitch gears were verified as meeting American Gear Manufacturing Association (AGMA) quality class 12. One-half of the gears were randomly selected for coating. The method of coating was selected to achieve desired adherence, toughness, hardness, and low-friction characteristics. First the gears to be coated were prepared by blasting (vapor honing) with Al2O3 particles and cleaning. Then, the gears were provided with a thin adhesion layer of elemental chromium followed by magnetron sputtering of the outer coating consisting of carbon (70 at.%), hydrogen (15 at.%), tungsten (12 at.%), and nickel (3 at.%) (atomic percent at the surface). In total, the coating thickness was about 2.5 to 3 microns. As compared with the steel substrate, the coated surface was harder by a factor of about 2 and had a smaller elastic modulus. All gears were tested using a 5-centistoke synthetic oil, a 10,000-rpm rotation speed, and a hertzian contact stress of at least 1.7 GPa (250 ksi). Tests were run until either surface fatigue occurred or 300 million stress cycles were completed. Tests were run using either a pair of uncoated gears or a pair of coated gears (coated gears mated with uncoated gears were not evaluated). The fatigue test results, shown on Weibull coordinates in the graph, demonstrate that the coating provided substantially longer fatigue lives even though some of the coated gears endured larger stresses. The increase in fatigue life was a factor of about 5 and the statistical confidence for the improvement is high (greater than 99 percent). Examination of the tested gears revealed substantial reductions of total wear for coated gears in comparison to uncoated gears. The coated gear surface topography changed with running, with localized areas of the tooth surface becoming smoother with running. Theories explaining how coatings can extend gear fatigue lives are research topics for coating, tribology, and fatigue specialists. This work was done as a partnership between NASA, the U.S. Army Research Laboratory, United Technologies Research Corporation, and Sikorsky Aircraft.

Krantz, Timothy L.↗

NASA NTRS2003

Increased Surface Fatigue Lives of Spur Gears by Application of a Coating

Hard coatings have potential for increasing gear surface fatigue lives. Experiments were conducted using gears both with and without a metal-containing, carbonbased coating. The gears were case-carburized AISI 9310 steel spur gears. Some gears were provided with the coating by magnetron sputtering. Lives were evaluated by accelerated life tests. For uncoated gears, all of fifteen tests resulted in fatigue failure before completing 275 million revolutions. For coated gears, eleven of the fourteen tests were suspended with no fatigue failure after 275 million revolutions. The improved life owing to the coating, approximately a six-fold increase, was a statistically significant result.

Krantz, Timothy L.↗

NASA NTRS2002

Software for Statistical Analysis of Weibull Distributions with Application to Gear Fatigue Data: User Manual with Verification

The Weibull distribution has been widely adopted for the statistical description and inference of fatigue data. This document provides user instructions, examples, and verification for software to analyze gear fatigue test data. The software was developed presuming the data are adequately modeled using a two-parameter Weibull distribution. The calculations are based on likelihood methods, and the approach taken is valid for data that include type 1 censoring. The software was verified by reproducing results published by others.

Krantz, Timothy L.↗

NASA NTRS2001

Modeling, Modal Properties, and Mesh Stiffness Variation Instabilities of Planetary Gears

Planetary gear noise and vibration are primary concerns in their applications in helicopters, automobiles, aircraft engines, heavy machinery and marine vehicles. Dynamic analysis is essential to the noise and vibration reduction. This work analytically investigates some critical issues and advances the understanding of planetary gear dynamics. A lumped-parameter model is built for the dynamic analysis of general planetary gears. The unique properties of the natural frequency spectra and vibration modes are rigorously characterized. These special structures apply for general planetary gears with cyclic symmetry and, in practically important case, systems with diametrically opposed planets. The special vibration properties are useful for subsequent research. Taking advantage of the derived modal properties, the natural frequency and vibration mode sensitivities to design parameters are investigated. The key parameters include mesh stiffnesses, support/bearing stiffnesses, component masses, moments of inertia, and operating speed. The eigen-sensitivities are expressed in simple, closed-form formulae associated with modal strain and kinetic energies. As disorders (e.g., mesh stiffness variation. manufacturing and assembling errors) disturb the cyclic symmetry of planetary gears, their effects on the free vibration properties are quantitatively examined. Well-defined veering rules are derived to identify dramatic changes of natural frequencies and vibration modes under parameter variations. The knowledge of free vibration properties, eigen-sensitivities, and veering rules provide important information to effectively tune the natural frequencies and optimize structural design to minimize noise and vibration. Parametric instabilities excited by mesh stiffness variations are analytically studied for multi-mesh gear systems. The discrepancies of previous studies on parametric instability of two-stage gear chains are clarified using perturbation and numerical methods. The operating conditions causing parametric instabilities are expressed in closed-form suitable for design guidance. Using the well-defined modal properties of planetary gears, the effects of mesh parameters on parametric instability are analytically identified. Simple formulae are obtained to suppress particular instabilities by adjusting contact ratios and mesh phasing.

Parker, Robert G.↗

NASA NTRS1999

Metrology Evaluation of Superfinished Gears Completed

Gears, bearings, and similar mechanical elements transmit loads through the surfaces that are in contact with one another. Thus, the fatigue lives of gears can be improved by providing smoother tooth surfaces. At the NASA Lewis Research Center, we completed a metrology evaluation of one method for making gears with a highly polished, mirrorlike surface. The polished gears were measured carefully. The measurement data showed that the polishing process did, indeed, reduce the surface roughness but did not change the overall tooth shape in any harmful way. This work was done as a partnership of NASA, the U.S. Army, and the University of Wales. NASA provided conventionally ground gear specimens and has begun testing to determine the fatigue lives of the superfinished gears. Under contract, the University of Wales superfinished the gears and inspected them before and after the superfinishing operation. The U.S. Army European Research Office provided the funds and procured the contract with the University of Wales.

Krantz, Timothy L.↗

NASA NTRS1998

Load Distribution in Transmissions "Split"

The transmission system of a helicopter must meet particularly critical requirements. It must transmit engine power to the rotor, at the same time ensuring a typical speed reduction of 60 to 1. It must also be safe, reliable, light, and reach a high level of performance while, at the same time, it must produce few vibrations and little noise. Helicopter transmissions have achieved high-level performances thanks to the combination of analyses, experiments, and the application of practical field experience. However, the new generation of helicopters will require transmission systems that are even safer, lighter, less noisy, and more reliable.

Krantz, Timothy L.↗

NASA NTRS1996

Experimental Study of Split-Path Transmission Load Sharing

Split-path transmissions are promising, attractive alternatives to the common planetary transmissions for helicopters. The split-path design offers two parallel paths for transmitting torque from the engine to the rotor. Ideally, the transmitted torque is shared equally between the two load paths; however, because of manufacturing tolerances, the design must be sized to allow for other than equal load sharing. To study the effect of tolerances, experiments were conducted using the NASA split-path test gearbox. Two gearboxes, nominally identical except for manufacturing tolerances, were tested. The clocking angle was considered to be a design parameter and used to adjust the load sharing of an otherwise fixed design. The torque carried in each path was measured for a matrix of input torques and clocking angles. The data were used to determine the optimal value and a tolerance for the clocking angles such that the most heavily loaded split path carried no greater than 53 percent of an input shaft torque of 367 N-m. The range of clocking angles satisfying this condition was -0.0012 +/- 0.0007 rad for box 1 and -0.0023 +/- 0.0009 rad for box 2. This study indicates that split-path gearboxes can be used successfully in rotorcraft and can be manufactured with existing technology.

Krantz, Timothy L.↗

NASA NTRS1996

A Method to Analyze and Optimize the Load Sharing of Split Path Transmissions

Split-path transmissions are promising alternatives to the common planetary transmissions for rotorcraft. Heretofore, split-path designs proposed for or used in rotorcraft have featured load-sharing devices that add undesirable weight and complexity to the designs. A method was developed to analyze and optimize the load sharing in split-path transmissions without load-sharing devices. The method uses the clocking angle as a design parameter to optimize for equal load sharing. In addition, the clocking angle tolerance necessary to maintain acceptable load sharing can be calculated. The method evaluates the effects of gear-shaft twisting and bending, tooth bending, Hertzian deformations within bearings, and movement of bearing supports on load sharing. It was used to study the NASA split-path test gearbox and the U.S. Army's Comanche helicopter main rotor gearbox. Acceptable load sharing was found to be achievable and maintainable by using proven manufacturing processes. The analytical results compare favorably to available experimental data.

Krantz, Timothy L.↗

NASA NTRS1995

Minimization of the Vibration Energy of Thin-Plate Structures and the Application to the Reduction of Gearbox Vibration

While the vibration analysis of gear systems has been developed, a systematic approach to the reduction of gearbox vibration has been lacking. The technique of reducing vibration by shifting natural frequencies is proposed here for gearboxes and other thin-plate structures using the theories of finite elements, modal analysis, and optimization. A triangular shell element with 18 degrees of freedom is developed for structural and dynamic analysis. To optimize, the overall vibration energy is adopted as the objective function to be minimized at the excitation frequency by varying the design variable (element thickness) under the constraint of overall constant weight. Modal analysis is used to determine the sensitivity of the vibration energy as a function of the eigenvalues and eigenvectors. The optimum design is found by the gradient projection method and a unidimensional search procedure. By applying the computer code to design problems for beams and plates, it was verified that the proposed method is effective in reducing vibration energy. The computer code is also applied to redesign the NASA Lewis gear noise rig test gearbox housing. As one example, only the shape of the top plate is varied, and the vibration energy levels of all the surfaces are reduced, yielding an overall reduction of 1/5 compared to the initial design. As a second example, the shapes of the top and two side plates are varied to yield an overall reduction in vibration energy of 1/30.

Inoue, Katsumi↗

NASA NTRS1995

Vibration Analysis of a Split Path Gearbox

Split path gearboxes can be attractive alternatives to the common planetary designs for rotorcraft, but because they have seen little use, they are relatively high risk designs. To help reduce the risk of fielding a rotorcraft with a split path gearbox, the vibration and dynamic characteristics of such a gearbox were studied. A mathematical model was developed by using the Lagrangian method, and it was applied to study the effect of three design variables on the natural frequencies and vibration energy of the gearbox. The first design variable, shaft angle, had little influence on the natural frequencies. The second variable, mesh phasing, had a strong effect on the levels of vibration energy, with phase angles of 0 deg and 180 deg producing low vibration levels. The third design variable, the stiffness of the shafts connecting the spur gears to the helical pinions, strongly influenced the natural frequencies of some of the vibration modes, including two of the dominant modes. We found that, to achieve the lowest level of vibration energy, the natural frequencies of these two dominant modes should be less than those of the main excitation sources.

Krantz, Timothy L.↗

NASA NTRS1994

Dynamics of a split torque helicopter transmission

Split torque designs, proposed as alternatives to traditional planetary designs for helicopter main rotor transmissions, can save weight and be more reliable than traditional designs. This report presents the results of an analytical study of the system dynamics and performance of a split torque gearbox that uses a balance beam mechanism for load sharing. The Lagrange method was applied to develop a system of equations of motion. The mathematical model includes time-varying gear mesh stiffness, friction, and manufacturing errors. Cornell's method for calculating the stiffness of spur gear teeth was extended and applied to helical gears. The phenomenon of sidebands spaced at shaft frequencies about gear mesh fundamental frequencies was simulated by modeling total composite gear errors as sinusoid functions. Although the gearbox has symmetric geometry, the loads and motions of the two power paths differ. Friction must be considered to properly evaluate the balance beam mechanism. For the design studied, the balance beam is not an effective device for load sharing unless the coefficient of friction is less than 0.003. The complete system stiffness as represented by the stiffness matrix used in this analysis must be considered to precisely determine the optimal tooth indexing position.

Krantz, Timothy L.↗

NASA NTRS1994

NASA/Army Rotorcraft Transmission Research, a Review of Recent Significant Accomplishments

A joint helicopter transmission research program between NASA Lewis Research Center and the U.S. Army Research Lab has existed since 1970. Research goals are to reduce weight and noise while increasing life, reliability, and safety. These research goals are achieved by the NASA/Army Mechanical Systems Technology Branch through both in-house research and cooperative research projects with university and industry partners. Some recent significant technical accomplishments produced by this cooperative research are reviewed. The following research projects are reviewed: oil-off survivability of tapered roller bearings, design and evaluation of high contact ratio gearing, finite element analysis of spiral bevel gears, computer numerical control grinding of spiral bevel gears, gear dynamics code validation, computer program for life and reliability of helicopter transmissions, planetary gear train efficiency study, and the Advanced Rotorcraft Transmission (ART) program.

Krantz, Timothy L.↗

NASA NTRS1993

Mechanical Systems Technology Branch research summary, 1985 - 1992

A collection of significant accomplishments from the research of the Mechanical Systems Technology Branch at the NASA Lewis Research Center completed during the years 1985-1992 is included. The publication highlights and accomplishments made in bearing and gearing technology through in-house research, university grants, and industry contracted projects. The publication also includes a complete listing of branch publications for these years.

Krantz, Timothy L.↗

NASA NTRS1992

Gear tooth stress measurements of two helicopter planetary stages

Two versions of the planetary reduction stages from U.S. Army OH-58 helicopter main rotor transmissions were tested at NASA Lewis. One sequential and one nonsequential planetary were tested. Sun gear and ring gear teeth strains were measured, and stresses were calculated from the strains. The alternating stress at the fillet of both the loaded and unloaded sides of the teeth and at the root of the sun gear teeth are reported. Typical stress variations as the gear tooth moves through mesh are illustrated. At the tooth root location of the thin rimmed sun gear, a significant stress was produced by a phenomenon other than the passing of a planet gear. The load variation among the planets was studied. Each planet produced its own distinctive load distribution on the ring and sun gears. The load variation was less for a three planet, nonsequential design as compared to that of a four planet, sequential design. The reported results enhance the data base for gear stress levels and provide data for the validation of analytical methods.

Krantz, Timothy L.↗

NASA NTRS1990

Experimental and analytical evaluation of efficiency of helicopter planetary stage

The efficiency of a helicopter transmission planetary stage was studied both experimentally and analytically. Experiments were done by using a back-to-back, test-and-slave arrangement. The experiments were a parametric study of the effects of operating conditions on efficiency. In order to enhance the analysis, a model was developed that calculates the power required for the meshing gears to displace oil trapped between the gear teeth. In general, the analysis predicted higher efficiencies than were measured. The results of this study were compared with those of other studies.

Krantz, Timothy L.↗