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At least 73 records · Page 4

Dynamic measurements of gear tooth friction and load

As part of a program to study fundamental mechanisms of gear noise, static and dynamic gear tooth strain measurements were made on the NASA gear-noise rig. Tooth-fillet strains from low-contact ratio-spur gears were recorded for 28 operating conditions. A method is introduced whereby strain gage measurements taken from both the tension and compression sides of a gear tooth can be transformed into the normal and frictional loads on the tooth. This technique was applied to both the static and dynamic strain data. The static case results showed close agreement with expected results. For the dynamic case, the normal-force computation produced very good results, but the friction results, although promising, were not as accurate. Tooth sliding friction strongly affected the signal from the strain gage on the tensionside of the tooth. The compression gage was affected by friction to a much lesser degree. The potential of the method to measure friction force was demonstrated, but further refinement will be required before this technique can be used to measure friction forces dynamically with an acceptable degree of accuracy.

Rebbechi, Brian↗

Friction and oxidative wear of 440C ball bearing steels under high load and extreme bulk temperatures

Unlubricated sliding friction and wear of 440C steels in an oxygen environment have been studied under a variety of load, speed, and temperature ranging from approximately -185 to 675 deg C. A specially designed test apparatus with a ball-on-flat geometry has been used for this purpose. The observed dependencies of the initial coefficient of friction, the average dynamic coefficient of friction, and the wear rate on load, speed, and test temperatures have been examined from the standpoint of existing theories of friction and wear. High contact temperatures are generated during the sliding friction, causing rapid oxidation and localized surface melting. A combination of fatigue, delamination, and loss of hardness due to tempering of the martensitic structure is responsible for the high wear rate observed and the coefficient of friction.

Chaudhuri, Dilip K.↗

Analog-computer investigation of effects of friction and preload on the dynamic longitudinal characteristics of a pilot-airplane combination

With an electric analog computer, an investigation has been made of the effects of control frictions and preloads on the transient longitudinal response of a fighter airplane during abrupt small attitude corrections. The simulation included the airplane dynamics, powered control system, feel system, and a simple linearized pseudopilot. Control frictions at the stick pivot and at the servo valve as well as preloads of the stick and valve were considered individually and in combinations. It is believed that the results which are presented in the form of time histories and vector diagrams present a more detailed illustration of the effects of stray forces and compensating forces in the longitudinal control system than has previously been available. Consistent with the results of previous studies, the present results show that any of thesefour friction and preload forces caused some deterioration of the response. However, even a small amount of valve friction caused an oscillatory pitching response during which the phasing of the valve friction was such that it caused energy to be fed into the pitching oscillation of the airplane. Of the other friction and preload forces which were considered, it was found that stick preload was close to 180 degrees out of phase with valve friction and thus could compensate in large measure for valve friction as long as the cycling of the stick encompassed the trim point. Either stick friction or valve preload provided a smaller stabilizing effect primarily through a reduction in the amplitude of the resultant force vector acting on the control system. Some data were obtained on the effects of friction when the damping or inertia of the control system or the pilot lag was varied.

Crane, Harold L↗

Analog-Computer Investigation of Effects of Friction and Preload on the Dynamic Longitudinal Characteristics of a Pilot-Airplane Combination

With an electric analog computer, an investigation has been made of the effects of control frictions and preloads on the transient longitudinal response of a fighter airplane during abrupt small attitude corrections. The simulation included the airplane dynamics, powered control system, feel system, and a simple linearized pseudopilot. Control frictions at the stick pivot and at the servo valve as well as preloads of the stick and valve were considered individually and in combinations. It is believed that the results which are presented in the form of time histories and vector diagrams present a more detailed illustration of the effects of stray forces and compensating forces in the longitudinal control system than has previously been available. Consistent with the results of previous studies, the present results show that any of these four friction and preload forces caused some deterioration of the response. However, even a small amount of valve friction caused an oscillatory pitching response during which the phasing of the valve friction was such that it caused energy to be fed into the pitching oscillation of the air-plane. Of the other friction and preload forces which were considered, it was found that stick preload was close to 180 deg. out of phase with valve friction and thus could compensate in large measure for valve friction as long as the cycling of the stick encompassed the trim point. Either stick friction or valve preload provided a smaller stabilizing effect primarily through a reduction in the amplitude of the resultant force vector acting on the control system. Some data were obtained on the effects of friction when the damping or inertia of the control system or the pilot lag was varied.

Crane, Harold L.↗

On dynamic loads in parallel shaft transmissions. 2: Parameter study

Solutions to the governing equations of a spur gear transmission model, developed in NASA TM-100180 (AVSCOM TM-87-C-2), are presented. Factors affecting the dynamic load are identified. It is found that the dynamic load increases with operating speed up to a system natural frequency. At operating speeds beyond the natural frequency the dynamic load decreases dramatically. Also. it is found that the applied load and shaft inertia have little effect on the dynamic load. Damping and friction decrease the dynamic load. Finally, tooth stiffness has a significant effect on dynamic loading; the higher the stiffness, the lower the dynamic loading. Also, the higher the stiffness the higher the rotating speed required for dynamic response.

Lin, Edward Hsiang-Hsi↗

Control and dynamics of an anti-friction levitation system

A novel anti-friction levitator concept has been devised and analytically evaluated to overcome support bearing friction and thereby minimize the structural damping of the Large Spacecraft Control Laboratory (LSCL) experiment structure at JPL. A dynamic model and controller design have been developed for the new levitation system. Simulation results show excellent system performance even when the system is subjected to significant measurement noise and hardware saturation effects.

Ih, C.-H. C.↗

Internal Friction And Instabilities Of Rotors

Report describes study of effects of internal friction on dynamics of rotors prompted by concern over instabilities in rotors of turbomachines. Theoretical and experimental studies described. Theoretical involved development of nonlinear mathematical models of internal friction in three joints found in turbomachinery - axial splines, Curvic(TM) splines, and interference fits between smooth cylindrical surfaces. Experimental included traction tests to determine the coefficients of friction of rotor alloys at various temperatures, bending-mode-vibration tests of shafts equipped with various joints and rotordynamic tests of shafts with axial-spline and interference-fit joints.

Walton, J.↗

Transient Response Dynamic Module Modifications to Include Static and Kinetic Friction Effects

A methodology that supports forced transient response dynamic solutions when both static and kinetic friction effects are included in a structural system model is described. Modifications that support this type of nonlinear transient response solution are summarized for the transient response dynamics (TRD) NASTRAN module. An overview of specific modifications for the NASTRAN processing subroutines, INITL, TRD1C, and TRD1D, are described with further details regarding inspection of nonlinear input definitions to define the type of nonlinear solution required, along with additional initialization requirements and specific calculation subroutines to successfully solve the transient response problem. The extension of the basic NASTRAN nonlinear methodology is presented through several stages of development to the point where constraint equations and residual flexibility effects are introduced into the finite difference Newmark-Beta recurrsion formulas. Particular emphasis is placed on cost effective solutions for large finite element models such as the Space Shuttle with friction degrees of freedom between the orbiter and payloads mounted in the cargo bay. An alteration to the dynamic finite difference equations of motion is discussed, which allows one to include friction effects at reasonable cost for large structural systems such as the Space Shuttle. Data are presented to indicate the possible impact of transient friction loads to the payload designer for the Space Shuttle. Transient response solution data are also included, which compare solutions without friction forces and those with friction forces for payloads mounted in the Space Shuttle cargo bay. These data indicate that payload components can be sensitive to friction induced loads.

Misel, J. E.↗

The Evolution of Friction Stir Welding Theory at Marshall Space Flight Center

From 1995 to the present the friction stir welding (FSW) process has been under study at Marshall Space Flight Center (MSFC). This is an account of the progressive emergence of a set of conceptual tools beginning with the discovery of the shear surface, wiping metal transfer, and the invention of a kinematic model and making possible a treatment of both metallurgical structure formation and process dynamics in friction stir welding from a unified point of view. It is generally observed that the bulk of the deformation of weld metal around the FSW pin takes place in a very narrow, almost discontinuous zone with high deformation rates characteristic of metal cutting. By 1999 it was realized that this zone could be treated as a shear surface like that in simple metal cutting models. At the shear surface the seam is drawn out and compressed and pressure and flow conditions determine whether or not a sound weld is produced. The discovery of the shear surface was followed by the synthesis of a simple 3- flow kinematic model of the FSW process. Relative to the tool the flow components are: (1) an approaching translational flow at weld speed V, (2) a rotating cylindrical plug flow with the angular velocity of the tool , and (3) a relatively slow ring vortex flow (like a smoke ring) encircling the tool and driven by shoulder scrolls and pin threads. The rotating plug flow picks up an element of weld metal, rotates it around with the tool, and deposits it behind the tool ( wiping metal transfer ); it forms plan section loops in tracers cut through by the tool. Radially inward flow from the ring vortex component retains metal longer in the rotating plug and outward flow expels metal earlier; this interaction forms the looping weld seam trace and the tongue and groove bimetallic weld contour. The radial components of the translational and ring vortex flows introduce parent metal intrusions into the small grained nugget material close to the tool shoulder; if this feature is pronounced, nugget collapse may result. Certain weld features, in particular internal banding seen in transverse section as onion rings and associated surface ridges called tool marks , have long implied an oscillation flow component, but have only recently been attributed in the literature to tool eccentricity. Rotating plug shape, typically a hollow cylinder flared at the end where it sticks to the shoulder, varies as pressure distribution on the tool determines where sticking occurs. Simplified power input estimates balanced against heat loss estimates give reasonable temperature estimates, explain why the power requirement changes hardly at all over a wide range of RPM s, and yield isotherms that seem to fall along boundaries of parameter windows of operation.

Nunes, Arthur C.↗

Multimodal Friction Ignition Tester

The multimodal friction ignition tester (MFIT) is a testbed for experiments on the thermal and mechanical effects of friction on material specimens in pressurized, oxygen-rich atmospheres. In simplest terms, a test involves recording sensory data while rubbing two specimens against each other at a controlled normal force, with either a random stroke or a sinusoidal stroke having controlled amplitude and frequency. The term multimodal in the full name of the apparatus refers to a capability for imposing any combination of widely ranging values of the atmospheric pressure, atmospheric oxygen content, stroke length, stroke frequency, and normal force. The MFIT was designed especially for studying the tendency toward heating and combustion of nonmetallic composite materials and the fretting of metals subjected to dynamic (vibrational) friction forces in the presence of liquid oxygen or pressurized gaseous oxygen test conditions approximating conditions expected to be encountered in proposed composite material oxygen tanks aboard aircraft and spacecraft in flight. The MFIT includes a stainless-steel pressure vessel capable of retaining the required test atmosphere. Mounted atop the vessel is a pneumatic cylinder containing a piston for exerting the specified normal force between the two specimens. Through a shaft seal, the piston shaft extends downward into the vessel. One of the specimens is mounted on a block, denoted the pressure block, at the lower end of the piston shaft. This specimen is pressed down against the other specimen, which is mounted in a recess in another block, denoted the slip block, that can be moved horizontally but not vertically. The slip block is driven in reciprocating horizontal motion by an electrodynamic vibration exciter outside the pressure vessel. The armature of the electrodynamic exciter is connected to the slip block via a horizontal shaft that extends into the pressure vessel via a second shaft seal. The reciprocating horizontal motion can be chosen to be random with a flat spectrum over the frequency range of 10 Hz to 1 kHz, or to be sinusoidal at any peak-to-peak amplitude up to 0.8 in. (.2 cm) and fixed or varying frequency up to 1 kHz. The temperatures of the specimen and of the vessel are measured by thermocouples. A digital video camera mounted outside the pressure vessel is aimed into the vessel through a sapphire window, with its focus fixed on the interface between the two specimens. A position transducer monitors the displacement of the pneumatic-cylinder shaft. The pressure in the vessel is also monitored. During a test, the output of the video camera, the temperatures, and the pneumatic-shaft displacement are monitored and recorded. The test is continued for a predetermined amount of time (typically, 10 minutes) or until either (1) the output of the position transducer shows a sudden change indicative of degradation of either or both specimens, (2) ignition or another significant reaction is observed, or (3) pressure in the vessel increases beyond a pre-set level that triggers an automatic shutdown.

Davis, Eddie↗

Physics-Based Modeling and Simulation of Self-Reacting Friction Stir Welding Using Computational Fluid Dynamics

A physics-based model was developed to simulate the behavior of material in a self-reacting friction stir welding (SR-FSW) process for the joining of metals. This steady-state model builds upon fundamental computational fluid dynamic (CFD) principles within Ansys Fluent to solve the discretized equations. The effective viscosity is calculated using a viscoplastic model using a Sheppard-Wright formulation of flow stress. Numerous advancements have been made in the incorporated physics including (1) temperature-dependent material properties; (2) locally adaptable flow and thermal boundary conditions; and (3) adapting material properties in nugget in response to microstructural changes. Simulation strategies to accelerate computation and improve numerical stability include adapting the mesh refinement and solver relaxation factors during simulation. The result is a highly robust and computationally efficient model capable of providing the material flow and temperature history across the domain. As material history determines the local microstructure and ultimately weld strength, an accurate and detailed physics-based model has the potential to accelerate SR-FSW process development. The model is highly adaptable to changes in process parameters, tool design, or alloy.

Process Modeling↗

A Plasma Aerocapture and Entry System for Manned Missions and Planetary Deep Space Orbiters

A rapid mission to Mars requires a large change in vehicle velocity upon arrival to establish a stable orbit. This demand is even greater for a Neptune science, requiring many kilometers per second of V. It is clear from past mission studies that a manned Mars mission and deep space planetary orbiters require aerobraking and aerocapture which use aerodynamic drag forces to slow the spacecraft. Aerocapture would enable long term studies of the outer planets and moons that would not be possible with existing braking methodologies. While the ability to utilize these atmospheres to slow down and capture spacecraft would dramatically reduce the cost, launch mass, and travel time, currently planned approaches require significant additional spacecraft mass and risk as the spacecraft must descend deep into the planetary atmosphere in order to produce significant drag on a relatively small aeroshell. The plasma based Magnetoshell being developed in this program holds the potential to perform the desired braking with significantly increased drag and control while dramatically reducing mass. Most importantly, this technology significantly lowers the risk involved with aerocapture thereby making manned planetary missions possible. The fundamental physics of the Magnetoshell is based on demonstrated experimental results. Successful implementation will dramatically decrease radiation exposures, mission risk, launch cost, and launch mass. Implementation of aerobraking by employing a solid deflector or aeroshell as a method for orbit insertion and circularization has been successfully demonstrated in the past, resulting in launch mass savings greater than 50%. In order to reduce the effect of frictional heating and dynamic pressure on the typically fragile aeroshell, or worse solar panels, the braking must be distributed over many orbital passes at a high altitude in the less dense regions of the atmosphere. It can thus take several months for a meter-scale, 1000 kg, aeroshell to execute the many elliptic orbital passes through the atmosphere to achieve the required V. This rather slow method of braking not only reduces frictional heating and dynamic forces, but also avoids unpredictable dynamic behavior due to turbulence, as well as unknown and seasonally variable atmospheric composition and temperature which has led to dangerous, mission-critical events. For exploration class missions such as DRA 5.0 aerocapture and Thermal Protection Systems (TPS) are proposed for breaking at Mars for cargo missions. Traditional aerocapture is considered too risky for manned missions. Even with the enormous mass savings that aerocapture allows, it still requires 80 tons of aeroshell and significantly increased launch mass and propellant. As will be shown, by using Magnetoshells for aerobraking, the DRA 5.0 mission will save 224 metric tons (MT) and greater than $2 B in launch costs. Beyond the dramatic savings for existing mission architectures, a low-mass, risk-free aerocapture system would allow much more rapid missions to Mars and deep space orbiters by allowing direct, faster trajectories. As will be shown, the plasma Magnetoshell Aerobraking, Aerocapture, and Entry System (AAES) not only reduces mass and cost while enabling significant new mission architectures, but also significantly reduces radiation exposures by decreasing trip times.

Manned Missions↗