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NASA NTRS2005

Improved Gear Shapes for Face Worm Gear Drives

Shapes different from the traditional ones have been proposed for face worm gears and for conical and cylindrical worms that mesh with them. The proposed shapes are based on the concept of generating a face worm gear surface by use of a tilted head cutter instead of by the traditional use of a hob. (As used here, head cutter is also meant to signify, alternatively, a head grinding tool.) The gear-surface-generation equipment would be similar to that used for generation of spiral bevel and hypoid gears. In comparison with the corresponding traditional hob, a tilted head cutter according to the proposal would be larger, could be fabricated with greater precision, and would enable the generation of gear surfaces with greater precision and greater productivity. A face worm gear would be generated (see figure) by use of a tilted head cutter, the blades or grinding surfaces of which would have straight-line profiles. The tilt of the head cutter would prevent interference with teeth adjacent to the groove being cut or ground. A worm to mesh with the face worm gear would be generated by use of a tilted head cutter mounted on the cradle of a generating machine. The blades or grinding surfaces of the head cutter would have a parabolic profile and would deviate from the straight-line profiles of the head cutter for the face worm gear. The shortest distance between the worm and the cradle would follow a parabolic function during the cycle of meshing in the generating process to provide a parabolic function of transmission errors to the gear drive. The small mismatch between the profiles of the face-worm-gear and worm head cutters would make it possible to localize the bearing contact in the worm gear drive. The parabolic function of transmission errors could absorb discontinuous linear functions of transmission errors caused by errors of alignment; this could afford a significant benefit, in that such errors are main sources of noise and vibration in gear drives. The main advantage of using tilted head cutters is that cutting speeds are independent of the shape-generation processes, making it possible to choose cutting speeds that are optimum with respect to requirements to minimize temperatures and deformations during fabrication and improve the quality of finished parts.

Litvin, Faydor L.↗

NASA NTRS1994

Manual for automatic generation of finite element models of spiral bevel gears in mesh

The goal of this research is to develop computer programs that generate finite element models suitable for doing 3D contact analysis of faced milled spiral bevel gears in mesh. A pinion tooth and a gear tooth are created and put in mesh. There are two programs: Points.f and Pat.f to perform the analysis. Points.f is based on the equation of meshing for spiral bevel gears. It uses machine tool settings to solve for an N x M mesh of points on the four surfaces, pinion concave and convex, and gear concave and convex. Points.f creates the file POINTS.OUT, an ASCI file containing N x M points for each surface. (N is the number of node points along the length of the tooth, and M is nodes along the height.) Pat.f reads POINTS.OUT and creates the file tl.out. Tl.out is a series of PATRAN input commands. In addition to the mesh density on the tooth face, additional user specified variables are the number of finite elements through the thickness, and the number of finite elements along the tooth full fillet. A full fillet is assumed to exist for both the pinion and gear.

Bibel, G. D.↗

NASA NTRS1994

Characterizing the wake vortex signature for an active line of sight remote sensor

A recurring phenomenon, described as a wake vortex, develops as an aircraft approaches the runway to land. As the aircraft moves along the runway, each of the wing tips generates a spiraling and expanding cone of air. During the lifetime of this turbulent event, conditions exist over the runway which can be hazardous to following aircraft, particularly when a small aircraft is following a large aircraft. Left to themselves, these twin vortex patterns will converge toward each other near the center of the runway, harmlessly dissipating through interaction with each other or by contact with the ground. Unfortunately, the time necessary to disperse the vortex is often not predictable, and at busy airports can severely impact terminal area productivity. Rudimentary methods of avoidance are in place. Generally, time delays between landing aircraft are based on what is required to protect a small aircraft. Existing ambient wind conditions can complicate the situation. Reliable detection and tracking of a wake vortex hazard is a major technical problem which can significantly impact runway productivity. Landing minimums could be determined on the basis of the actual hazard rather than imposed on the basis of a worst case scenario. This work focuses on using a windfield description of a wake vortex to generate line-of-sight Doppler velocity truth data appropriate to an arbitrarily located active sensor such as a high resolution radar or lidar. The goal is to isolate a range Doppler signature of the vortex phenomenon that can be used to improve detection. Results are presented based on use of a simplified model of a wake vortex pattern. However, it is important to note that the method of analysis can easily be applied to any vortex model used to generate a windfield snapshot. Results involving several scan strategies are shown for a point sensor with a range resolution of 1 to 4 meters. Vortex signatures presented appear to offer potential for detection and tracking.

Heil, Robert Milton↗

NASA NTRS1976

Numerical Studies of Three-dimensional Breakdown in Trailing Vortex Wakes

Finite element, three dimensional relaxation methods are used to calculate the development of vortex wakes behind aircraft for a considerable downstream distance. The inclusion of a self-induction term in the solution, dependent upon local curvature and vortex core radius, permits calculation of finite lifetimes for systems for which infinite life would be predicted two dimensionally. The associated computer program is described together with single-pair, twin-pair, and multiple-pair studies carried out using it. It is found, in single-pair studies, that there is a lower limit to the wavelengths at which the Crow-type of instability can occur. Below this limit, self-induction effects cause the plane of the disturbance waves to rotate counter to the vortex direction. Self induction in two dimensionally generated twin spiral waves causes an increase in axial length which becomes more marked with decreasing initial wavelength. The time taken for vortex convergence toward the center plane is correspondingly increased. The limited parametric twin-pair study performed suggests that time-to-converge increases with increasing flap span. Limited studies of Boeing 747 configurations show correct qualitative response to removal of the outer flap and to gear deployment, as compared with wind tunnel and flight test experience.

Evans, P. F.↗

NASA NTRS1985

Gradually Acting Shaft Stop

Mechanism brakes rotation with minimal shock. Balls rising on spiral ramp generate large axial force on brake friction plates, thereby generating large braking torque. Counter triggers rise of ball. Brake used to automatically stop control mechanisms on aircraft and ships. Serves as spindle brake on machine tool. On robot, prevents overtravel of arm or holds it in fixed position.

Lang, D. J.↗

NASA NTRS2005

Fluid Bubble Eliminator

A gas-liquid separator uses a helical passageway to impart a spiral motion to a fluid passing therethrough. The centrifugal fore generated by the spiraling motion urges the liquid component of the fluid radially outward which forces the gas component radially inward. The gas component is then filtered through a gas-permeable, liquid-impervious membrane and discharged through a central passageway.

Gonda, Steve R.↗

NASA NTRS2005

Fluid bubble eliminator

Gonda, Steve R.↗

NASA NTRS2006

Centrifugal adsorption system

A gas-liquid separator uses a helical passageway to impart a spiral motion to a fluid passing therethrough. The centrifugal force generated by the spiraling motion urges the liquid component of the fluid radially outward which forces the gas component radially inward. The gas component is then separated through a gas-permeable, liquid-impervious membrane and discharged through a central passageway. A filter material captures target substances contained in the fluid.

Gonda, Steve R.↗

NASA NTRS1989

Generation and tooth contact analysis of spiral bevel gears with predesigned parabolic functions of transmission errors

A new approach for determination of machine-tool settings for spiral bevel gears is proposed. The proposed settings provide a predesigned parabolic function of transmission errors and the desired location and orientation of the bearing contact. The predesigned parabolic function of transmission errors is able to absorb piece-wise linear functions of transmission errors that are caused by the gear misalignment and reduce gear noise. The gears are face-milled by head cutters with conical surfaces or surfaces of revolution. A computer program for simulation of meshing, bearing contact and determination of transmission errors for misaligned gear has been developed.

Litvin, Faydor L.↗

NASA NTRS1993

Low cost antennas for MSAT vehicular applications

For Mobile MSAT applications a number of vehicular antennas have been developed that meet the program requirements. They are, however, costly to manufacture. Two antenna candidates are described here that provide adequate gain in the coverage zone and are also lower cost. One is the mast antenna that uses three or four element arrays of aquadrifilar helices. It generates omnidirectional pattern in azimuth and its beam is scanned in elevation. The second unit is a planar spiral antenna; it generates directional beams by a summation of the azimuthal modes. A variation of this antenna uses conical spirals to fulfill the same task. In both cases beam scanning is achieved by means of electronic switches rather than phase shifters, thus resulting in simpler configurations.

Shafai, L.↗

NASA NTRS1989

Computer-aided design of bevel gear tooth surfaces

This paper presents a computer-aided design procedure for generating bevel gears. The development is based on examining a perfectly plastic, cone-shaped gear blank rolling over a cutting tooth on a plane crown rack. The resulting impression on the plastic gear blank is the envelope of the cutting tooth. This impression and envelope thus form a conjugate tooth surface. Equations are presented for the locus of points on the tooth surface. The same procedures are then extended to simulate the generation of a spiral bevel gear. The corresponding governing equations are presented.

Shuo, Hung Chang↗

NASA NTRS1989

Computer aided design of bevel gear tooth surfaces

Chang, S. H.↗

NASA NTRS2014

Investigation of Spiral Bevel Gear Condition Indicator Validation Via AC-29-2C Using Damage Progression Tests

This report documents the results of spiral bevel gear rig tests performed under a NASA Space Act Agreement with the Federal Aviation Administration (FAA) to support validation and demonstration of rotorcraft Health and Usage Monitoring Systems (HUMS) for maintenance credits via FAA Advisory Circular (AC) 29-2C, Section MG-15, Airworthiness Approval of Rotorcraft (HUMS) (Ref. 1). The overarching goal of this work was to determine a method to validate condition indicators in the lab that better represent their response to faults in the field. Using existing in-service helicopter HUMS flight data from faulted spiral bevel gears as a "Case Study," to better understand the differences between both systems, and the availability of the NASA Glenn Spiral Bevel Gear Fatigue Rig, a plan was put in place to design, fabricate and test comparable gear sets with comparable failure modes within the constraints of the test rig. The research objectives of the rig tests were to evaluate the capability of detecting gear surface pitting fatigue and other generated failure modes on spiral bevel gear teeth using gear condition indicators currently used in fielded HUMS. Nineteen final design gear sets were tested. Tables were generated for each test, summarizing the failure modes observed on the gear teeth for each test during each inspection interval and color coded based on damage mode per inspection photos. Gear condition indicators (CI) Figure of Merit 4 (FM4), Root Mean Square (RMS), +/- 1 Sideband Index (SI1) and +/- 3 Sideband Index (SI3) were plotted along with rig operational parameters. Statistical tables of the means and standard deviations were calculated within inspection intervals for each CI. As testing progressed, it became clear that certain condition indicators were more sensitive to a specific component and failure mode. These tests were clustered together for further analysis. Maintenance actions during testing were also documented. Correlation coefficients were calculated between each CI, component, damage state and torque. Results found test rig and gear design, type of fault and data acquisition can affect CI performance. Results found FM4, SI1 and SI3 can be used to detect macro pitting on two more gear or pinion teeth as long as it is detected prior to progressing to other components or transitioning to another failure mode. The sensitivity of RMS to system and operational conditions limit its reliability for systems that are not maintained at steady state. Failure modes that occurred due to scuffing or fretting were challenging to detect with current gear diagnostic tools, since the damage is distributed across all the gear and pinion teeth, smearing the impacting signatures typically used to differentiate between a healthy and damaged tooth contact. This is one of three final reports published on the results of this project. In the second report, damage modes experienced in the field will be mapped to the failure modes created in the test rig. The helicopter CI data will then be re-processed with the same analysis techniques applied to spiral bevel rig test data. In the third report, results from the rig and helicopter data analysis will be correlated. Observations, findings and lessons learned using sub-scale rig failure progression tests to validate helicopter gear condition indicators will be presented.

gears↗

NASA NTRS1994

Low-Noise Spiral Bevel Gears

Modified spiral bevel gears that generate relatively little noise and vibration designed and fabricated for use in U.S. Army OH-58D helicopter. Noise reduced by 12 to 19 dB. Similar low-noise, low-vibration spiral bevel gears used in other helicopters, with consequent benefits in comfort and health of pilots and passengers, enhancement of pilots' performance and safety through reduction of audible distraction, and reduction in cost and weight of helicopters through reduction in amount of sound-proofing material. Low-noise, low-vibration spiral bevel gears also used in drive axles of cars and trucks for smoother, quieter rides.

Lewicki, David G.↗

NASA NTRS1986

Synthesis and Optimization of Spiral Bevel Gears

Two mathematical models help in optimizing design of spiral bevel gears. In essence, replace actual generated tooth surface with mathematical conjugate approximation. Tooth surfaces of spiral bevel gears replaced (or approximated) by conjugate tooth surfaces. Surfaces generated by two conical surface's rigidly connected with each other and in linear tangency along common generatrix of tool cones and by conical surface and surface of revolution in linear tangency along circle. Gears have widespread applications in transmission systems of helicopters, airplanes, trucks, automobiles, tanks, and many other machines.

Litvin, F. L.↗

NASA NTRS1993

Global-, local-, and intermediate-scale structures in prototype spiral galaxies

The relationship between galactic spiral structure and the matter in the underlying disk constitutes one of the central problems in galactic dynamics. In Bertin et al. (1989), disk matter characterized by a low-dispersive speed is shown to be capable of playing a key role in the generation of large-scale spiral structure. In Roberts et al. (1992), this self-gravitating, low-dispersion disk matter is shown to be capable of playing an essential role in the formation of structure on local and intermediate scales. Both in computed cases where large-scale spiral structure is present and in those where it is not, the same dominant physical processes and fundamental dynamical mechanisms are active on local scales. The new perception, in which large-scale and small-scale phenomena operate somewhat independently as evidenced in the computational studies, permits a range of flocculent, multiarmed, and grand design spiral types to be simulated. In particular, grand design galaxies with ragged appearances exhibiting spurs, arm branchings, and interarm bridges in addition to the major spiral arms, similar to those often observed, can be generated.

Roberts, William W., Jr.↗

NASA NTRS1977

Computer simulation of plasma and N-body problems

Any spiral structure in computer-generated galaxies is generally short lived and the final state is a rotating bar. The bar thus obtained rotates more slowly than the stars. It has been argued that core/halo components have a stabilizing effect on galaxies and result in longer lived spiral structure. However, numerical experiments with large fixed stellar components representing the core/halo component show that multiarmed spiral structure develops and persists for many rotations but only in an evolving manner. That is, the spiral structure is either wound up into a tight pattern or it is wound up and then reappears again. A recent study of the effect of fixed core/halo components does show that the bar instability is indeed inhibited by a sufficiently large fixed component. The present study determines the effect of a self-consistent (rather than fixed) core/halo component in order to show whether there are any instabilities (such as two-stream) or other important interactions present that may be suppressed with a fixed core. Also studied were the effects of finite thickness of the disk and of three-dimensional essentially spherical core/halo components.

Harries, W. L.↗

NASA NTRS1968

Lightweight heater generates high temperatures from low current

Double spiral molybdenum heater element uses low current, needs no insulation, and requires support only at the ends, which are also the power input points. Because there is no insulation or internal support necessary, the heater is lightweight. Its temperature potential will vary with its size and environment.

Hansen, E. L.↗