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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

Derivation of generalized transition/boundary conditions for planar multiple-layer structures

Infinite-order generalized impedance boundary conditions (GIBCs) and generalized sheet transition conditions (GSTCs) for planar multilayer configurations are developed via the Taylor series expansion method. The conditions are derived in a matrix product form where each matrix corresponds to a specific layer. An overall composite boundary/transition condition is obtained by making finite-order approximations to the elements of each matrix for the cases of 'low-contrast' and 'high-contrast' material layers. The accuracy of the truncated boundary conditions is examined by comparing their implied reflection and transmission coefficients with the corresponding exact coefficients. Design curves are also given which relate the maximum order of the conditions required to simulate a coating or layer of specific thickness and contrast. Expressions are then derived for the reflection and transmission coefficients of the GIBC/GSTC sheets, and these are compared to exact coefficients to demonstrate the validity of the derived GIBCs/GSTCs.

Ricoy, M. A.↗
NASA NTRS1990

TE scattering by a two-dimensional groove in a ground plane using higher order boundary conditions

Higher order boundary conditions involve derivatives of the fields beyond the first and were recently shown to be more effective than traditional first order conditions in modeling dielectric coatings and layers. In this report an application of a third order generalized boundary condition to scattering by a filled rectangular groove is presented. Deficiencies of such higher-order boundary conditions are addressed and a correction is proposed for the present case. As part of the process of examining and correcting the accuracy of the proposed generalized boundary conditions, an exact solution is developed and a comparison is provided with a solution based on the standard impedance boundary condition.

Barkeshli, Kasra↗
NASA NTRS1993

Performance under dichoptic versus binocular viewing conditions - Effects of attention and task requirements

Three experiments investigated subjects' ability to allocate attention and cope with task requirements under dichoptic versus binocular viewing conditions. Experiments 1 and 2 employed a target detection task in compound and noncompound stimuli, and Experiment 3 employed a relative-proximity judgment task. The tasks were performed in a focused attention condition in which subjects had to attend to the stimulus presented to one eye or field (under dichoptic and binocular viewing conditions, respectively) while ignoring the stimulus presented to the other eye or field, and in a divided attention condition in which subjects had to attend to the stimuli presented to both eyes or fields. Subjects' performance was affected by the interaction of attention conditions with task requirements, but it was generally the same under dichoptic and binocular viewing conditions. The more dependent the task was on finer discrimination, the more performance was impaired by divided attention. These results suggest that at least with discrete tasks and relatively short exposure durations, performance when each eye is presented with a separate stimulus is the same as when the entire field of stimulation is viewed by both eyes.

Kimchi, Ruth↗
NASA NTRS1947

A Method for Calculating the Heat Required for Windshield Thermal Ice Prevention Based on Extensive Flight Tests in Natural Icing Conditions

An equation is presented for calculating the heat flow required from the surface of an internally heated windshield in order to prevent the formation of ice accretions during flight in specified icing conditions. To ascertain the validity of the equation, comparison is made between calculated values of the heat required and measured values obtained for test windshields in actual flights in icing conditions. The test windshields were internally heated and provided data applicable to two common types of windshield configurations; namely the V-type and the type installed flush with the fuselage contours. These windshields were installed on a twin-engine cargo airplane and the icing flights were conducted over a large area of the United States during the winters of 1945-46 and 1946-47. In addition to the internally heated windshield investigation, some test data were obtained for a windshield ice-prevention system in which heated air was discharged into the windshield boundary layer. The general conclusions resulting from this investigation are as follows: 1) The amount of heat required for the prevention of ice accretions on both flush- and V-type windshields during flight in specified icing conditions can be calculated with a degree of accuracy suitable for design purposes. 2) A heat flow of 2000 to 2500 Btu per hour per square foot is required for complete and continuous protection of a V-type windshield in fight at speeds up to 300 miles per hour in a moderate cumulus icing condition. For the same degree of protection and the same speed range, a value of 1000 Btu per hour per square foot suffices in a moderate stratus icing condition. 3) A heat supply of 1000 Btu per hour per square foot is adequate for a flush windshield located well aft of the fuselage stagnation region, at speeds up to 300 miles per hour, for flight in both stratus and moderate cumulus icing conditions. 4) The external air discharge system of windshield thermal ice prevention is thermally inefficient and requires a heat supply approximately 20 times that required for an internal system having the same performance.

ICE FORMATION↗
NASA NTRS1945

Effect of Maximum Cruise-power Operation at Ultra-lean Mixture and Increased Spark Advance on the Mechanical Condition of Cylinder Components

A continuous 50-hour test was conducted to determine the effect of maximum cruise-power operation at ultra-lean fuel-air mixture and increased spark advance on the mechanical conditions of cylinder components. The test was conducted on a nine-cylinder air-cooled radial engine at the following conditions:brake horsepower, 750; engine speed, 1900 rpm; brake mean effective pressure, 172 pounds per square inch; fuel-air ratio, 0.052; spark advance, 30 deg B.T.C.; and maximum rear-spark-plug-bushing temperature, 400 F. In addition to the data on corrosion and wear, data are presented and briefly discussed on the effect of engine operation at the conditions of this test on economy, knock, preignition, and mixture distribution. Cylinder, piston, and piston-ring wear was small and all cylinder component were in good condition at the conclusion of the 50-hour test except that all exhaust-valve guides were bellmouthed beyond the Army's specified limit and one exhaust-valve face was lightly burned. It is improbable that the light burning in one spot of the valve face would have progressed further because the burn was filled with a hard deposit so that the valve face formed an unbroken seal and the mating seat showed no evidence of burning. The bellmouthing of the exhaust-valve guides is believed to have been a result of the heavy carbon and lead-oxide deposits, which were present on the head end of the guided length of the exhaust-valve stem. Engine operational the conditions of this test was shown to result In a fuel saving of 16.8 percent on a cooled-power basis as compared with operation at the conditions recommended for this engine by the Army Air Forces for the same power.

ENGINE CYLINDERS-WEAR↗
NASA NTRS1994

Conditional statistics in a turbulent premixed flame derived from direct numerical simulation

The objective of this paper is to briefly introduce conditional moment closure (CMC) methods for premixed systems and to derive the transport equation for the conditional species mass fraction conditioned on the progress variable based on the enthalpy. Our statistical analysis will be based on the 3-D DNS database of Trouve and Poinsot available at the Center for Turbulence Research. The initial conditions and characteristics (turbulence, thermo-diffusive properties) as well as the numerical method utilized in the DNS of Trouve and Poinsot are presented, and some details concerning our statistical analysis are also given. From the analysis of DNS results, the effects of the position in the flame brush, of the Damkoehler and Lewis numbers on the conditional mean scalar dissipation, and conditional mean velocity are presented and discussed. Information concerning unconditional turbulent fluxes are also presented. The anomaly found in previous studies of counter-gradient diffusion for the turbulent flux of the progress variable is investigated.

Mantel, Thierry↗
NASA NTRS1997

Numerical Boundary Conditions for Computational Aeroacoustics Benchmark Problems

Category 1, Problems 1 and 2, Category 2, Problem 2, and Category 3, Problem 2 are solved computationally using the Dispersion-Relation-Preserving (DRP) scheme. All these problems are governed by the linearized Euler equations. The resolution requirements of the DRP scheme for maintaining low numerical dispersion and dissipation as well as accurate wave speeds in solving the linearized Euler equations are now well understood. As long as 8 or more mesh points per wavelength is employed in the numerical computation, high quality results are assured. For the first three categories of benchmark problems, therefore, the real challenge is to develop high quality numerical boundary conditions. For Category 1, Problems 1 and 2, it is the curved wall boundary conditions. For Category 2, Problem 2, it is the internal radiation boundary conditions inside the duct. For Category 3, Problem 2, they are the inflow and outflow boundary conditions upstream and downstream of the blade row. These are the foci of the present investigation. Special nonhomogeneous radiation boundary conditions that generate the incoming disturbances and at the same time allow the outgoing reflected or scattered acoustic disturbances to leave the computation domain without significant reflection are developed. Numerical results based on these boundary conditions are provided.

Tam, Chritsopher K. W.↗
NASA NTRS1997

Advances in Numerical Boundary Conditions for Computational Aeroacoustics

Advances in Computational Aeroacoustics (CAA) depend critically on the availability of accurate, nondispersive, least dissipative computation algorithm as well as high quality numerical boundary treatments. This paper focuses on the recent developments of numerical boundary conditions. In a typical CAA problem, one often encounters two types of boundaries. Because a finite computation domain is used, there are external boundaries. On the external boundaries, boundary conditions simulating the solution outside the computation domain are to be imposed. Inside the computation domain, there may be internal boundaries. On these internal boundaries, boundary conditions simulating the presence of an object or surface with specific acoustic characteristics are to be applied. Numerical boundary conditions, both external or internal, developed for simple model problems are reviewed and examined. Numerical boundary conditions for real aeroacoustic problems are also discussed through specific examples. The paper concludes with a description of some much needed research in numerical boundary conditions for CAA.

Tam, Christopher K. W.↗
NASA NTRS1998

A Formulation of Asymptotic and Exact Boundary Conditions Using Local Operators

In this paper we describe a systematic approach for constructing asymptotic boundary conditions for isotropic wave-like equations using local operators. The conditions take a recursive form with increasing order of accuracy. In three dimensions the recursion terminates and the resulting conditions are exact for solutions which are described by finite combinations of angular spherical harmonics. First, we develop the expansion for the two-dimensional wave equation and construct a sequence of easily implementable boundary conditions. We show that in three dimensions and analogous conditions are again easily implementable in addition to being exact. Also, we provide extensions of these ideas to hyperbolic systems. Namely, Maxwell's equations for TM waves are used to demonstrate the construction. Finally, we provide numerical examples to demonstrate the effectiveness of these conditions for a model problem governed by the wave equation.

Hagstrom, T.↗
NASA NTRS2000

Remote Sensing of In-Flight Icing Conditions: Operational, Meteorological, and Technological Considerations

Remote-sensing systems that map aircraft icing conditions in the flight path from airports or aircraft would allow icing to be avoided and exited. Icing remote-sensing system development requires consideration of the operational environment, the meteorological environment, and the technology available. Operationally, pilots need unambiguous cockpit icing displays for risk management decision-making. Human factors, aircraft integration, integration of remotely sensed icing information into the weather system infrastructures, and avoid-and-exit issues need resolution. Cost, maintenance, power, weight, and space concern manufacturers, operators, and regulators. An icing remote-sensing system detects cloud and precipitation liquid water, drop size, and temperature. An algorithm is needed to convert these conditions into icing potential estimates for cockpit display. Specification development requires that magnitudes of cloud microphysical conditions and their spatial and temporal variability be understood at multiple scales. The core of an icing remote-sensing system is the technology that senses icing microphysical conditions. Radar and microwave radiometers penetrate clouds and can estimate liquid water and drop size. Retrieval development is needed; differential attenuation and neural network assessment of multiple-band radar returns are most promising to date. Airport-based radar or radiometers are the most viable near-term technologies. A radiometer that profiles cloud liquid water, and experimental techniques to use radiometers horizontally, are promising. The most critical operational research needs are to assess cockpit and aircraft system integration, develop avoid-and-exit protocols, assess human factors, and integrate remote-sensing information into weather and air traffic control infrastructures. Improved spatial characterization of cloud and precipitation liquid-water content, drop-size spectra, and temperature are needed, as well as an algorithm to convert sensed conditions into a measure of icing potential. Technology development also requires refinement of inversion techniques. These goals can be accomplished with collaboration among federal agencies including NASA, the FAA, the National Center for Atmospheric Research, NOAA, and the Department of Defense. This report reviews operational, meteorological, and technological considerations in developing the capability to remotely map in-flight icing conditions from the ground and from the air.

Ryerson, Charles C.↗
NASA NTRS2003

Investigations of Mechanisms Associated with Nucleate Boiling Under Microgravity Conditions

In this work a building block type of approach is used so that a basic understanding of the processes that contribute to nucleate boiling heat fluxes under microgravity conditions can be developed. This understanding will lead to development of a mechanistic model for nucleate boiling heat transfer which could eventually be used as a design tool in space applications. Task Description Task 1: Fabrication of the Experimental Setup. Under this task, the test section and liquid holding and viewing chambers will be fabricated. Artificial cylinder cavities will be formed on silicon wafers. A single cavity and two or four cavities, with a prescribed spacing and size, will be formed. The desired nucleation wall superheat will be used to determine the size of the mouth of the cavities. Task 2: Experiments. The basic experiments for flow and temperature field around single and multiple (2 or 4 separated or merged bubbles growing on downward facing or inclined surfaces) will be carried out under normal gravity conditions. The experiments will be conducted at one atmosphere pressure, but liquid subcooling will be varied from 0 to 30C. Water and PF-5050 will be used as test liquids. Task 3: Analytical/Numerical Models. In this task, transient temperature and flow field in vapor and liquid will be determined during growth of a single bubble. Analysis will include the evolution of the vapor-liquid interface and development of microlayer underneath the bubbles. For merged bubbles, detailed calculations of flow and temperature field will be carried out for transient shapes of vapor stems supporting a large bubble and the corresponding evaporation rate. Flow and temperature field for a bubble sliding along a heated wall will also be determined. Microgravity conditions will be simulated and a framework of a numerical tool for prediction of nucleate boiling heat fluxes under microgravity conditions will be developed. Task 4: Experiments in a KC-135. To understand bubble growth and detachment behavior of single or large merged bubbles, boiling experiments will be conducted under low gravity (10-2 g) conditions of the aircraft. In these experiments, 'designed' surfaces will be used. Visual observations and heat transfer data will be taken, but holography will not be used. The apparatus used for laboratory experiments will also be employed for experiments in the aircraft. Task 5: Experiments in the Space Shuttle. Effort will be devoted for defining a boiling experiment to be conducted on a 'designed' surface. The experiment will provide microgravity data on bubble growth and departure. These data are needed for development of a credible model for nucleate boiling heat fluxes under microgravity conditions. The heat transfer data will also be obtained and will be used to validate the models.

Dhir, Vijay K.↗
NASA NTRS1972

Force-Strain Characteristics and Rupture-Load Capability of Viking-Type Suspension-Line Material Under Dynamic Loading Conditions

A series of tests has been conducted to investigate the elastic behavior of Viking-type suspension-line material under dynamic loading conditions. Results indicate that there is a decrease in both rupture-load capability and elongation at rupture as the test strain rate is increased. Preliminary examination of force-strain characteristics indicates that, on the average, the material exhibits some type of viscous effect which results in a greater force being produced, for a particular value of strain, under dynamic loading conditions than that produced under quasi-static loading conditions. A great deal of uncertainty exists in defining a priori the tensile properties of viscoelastic materials, such as nylon or dacron, under dynamic loading conditions. Additional uncertainty enters the picture when woven configurations such as suspension,line material are considered. To eliminate these uncertainties, with respect to the Viking parachute configuration, a test program has been conducted to obtain data on the tensile properties of Viking-type suspension-line material over a wide range of strain rates. Based on preliminary examination of these data, the following conclusions can be drawn: 1. Material rupture-load capability decreases as strain-rate is increased. At strain rates above 75 percent/sec, no rupture loads were observed which would meet the minimum tensile strength specification of 880 pounds. 2. The material, on the average, exhibits some type of viscous effect which, for a particular value of strain, produces a greater load under dynamic loading conditions than that produced under quasi-static loading conditions.

Poole, Lamont R.↗
NASA NTRS1978

System-state and operating condition sensitive control method and apparatus for electric power delivery systems

This invention provides a method and apparatus for determining a precise switching sequence for the power switching elements of electric power delivery systems of the on-off switching type and which enables extremely fast transient response, precise regulation and highly stable operation. The control utilizes the values of the power delivery system power handling network components, a desired output characteristic, a system timing parameter, and the externally imposed operating conditions to determine where steady state operations should be in order to yield desired output characteristics for the given system specifications. The actual state of the power delivery system is continuously monitored and compared to a state-space boundary which is derived from the desired equilibrium condition, and from the information obtained from this comparison, the system is moved to the desired equilibrium condition in one cycle of switching control. Since the controller continuously monitors the power delivery system's externally imposed operating conditions, a change in the conditions is immediately sensed and a new equilibrium condition is determined and achieved, again in a single cycle of switching control.

Burns, III, William Wesley↗
NASA NTRS2011

Challenges of Cold Conditioning and Static Testing the Second Ares Demonstration Motor (DM-2)

On August 31, 2010, a five-segment demonstration motor (DM) for the Ares program was successfully tested. A series of demonstration motors (DMs) will be tested in different conditioned environments to confirm they meet their design specifications. The second demonstration motor (DM-2) was the first cold motor. The motor needed to be subjected to sub-freezing temperatures for two months so that its internal propellant mean bulk temperature (PMBT) was approximately 40 F. Several challenges had to be overcome to make this a successful test. One challenge was to condition four field joints to get the O-rings approximately 32 F. This would be done by applying conditioning shrouds to externally cool each field joint after the test bay was pulled off. The purpose of this conditioning was to validate the new O-ring design and allow joint heaters to be eliminated. Another challenge was maintaining temperature requirements for components in the nozzle vectoring system. A separate heating system was used to warm these components during cold conditioning. There were 53 test objectives that required 764 channels of data to be recorded; 460 were specific to DM-2. This instrumentation had to be installed prior to conditioning, which meant the baseline process and timeline had to be modified to meet this time critical schedule.

Quinn, Shyla↗
NASA NTRS2012

Effect of Inflow Boundary Conditions on Hovering Tilt-Rotor Flows

A study on the effect of inflow turbulence boundary conditions on the local flow on and around a body in flight has been carried out. The study has been carried out using OVERFLOW2 flow solver using the default Spalart-Allmaras turbulence model in OVERFLOW. Many OVERFLOW turbulent flow simulations have been reported using the SA-fv3 model1 over the years. The present study demonstrates that the turbulence levels imposed as a boundary condition (b.c.) in the far-field as implemented in OVERFLOW are not correct. In fact, very low level of turbulence at the far-field boundary as implemented in OVERFLOW results in the SA-fv3 model predicting transition-like profiles on a given body. By choosing sufficiently high levels of the Reynolds number of turbulence, Rt, as a boundary condition, this anomalous behavior of SA-fv3 model is eliminated. Since numerous papers using OVERFLOW have been presented in the literature including that by the author2 using low level of inflow turbulence, it will be beneficial to the CFD community at large and in particular to the OVERFLOW community to understand this effect of the inflow b.c. in the SA-fv3 model. Various results reported over the years in domains such as high-lift applications, drag prediction applications and rotorcraft flow applications can be revisited using the new turbulence inflow boundary condition prescription as suggested in this study. It has been demonstrated in the literature that the effect of inflow turbulence level on the downstream development of flow is too important to be ignored. Demonstrative results are shown and compared with experiment for the case of hovering XV-15 rotor flow at a tip Reynolds number of 4.9 x 10(exp 6) and Mach number of 0.69 in Figs. 1 and 2 below. Fig. 1(a,b) shows skin friction predictions at radial station of r/R = 0.28 corresponding to 5 different inflow boundary conditions obtained with the SA-fv3 model. As the inflow turbulence is increased monotonically, from a value of Rt = 0.1 to 100.0 as shown in Fig. 1, a fully developed turbulent skin friction profile is realized progressively as shown in Fig. 1(b). Similarly skin friction results shown in Fig. 2(a,b) corresponding to radial stations of r/R = 0.72 reinforce the postulate made here that as the inflow turbulence level is increased gradually, fully turbulent on-the-blade simulation is realized uniformly. In the full paper extensive results on skin friction, pressure and velocity profiles as well as the Figure of Merit will be presented and compared with experiment that will illustrate the substantial effect of the inflow boundary conditions on the development of hovering rotor flow downstream.

Kaul, Upender K.↗
NASA NTRS2014

Alteration of Basaltic Glass to Mg/Fe-Smectite under Acidic Conditions: A Potential Smectite Formation Mechanism on Mars

Phyllosilicates of the smectite group including Mg- and Fe-saponite and Fe(III)-rich nontronite have been identified on Mars. Smectites are believed to be formed under neutral to alkaline conditions that prevailed on early Mars. This hypothesis is supported by the observation of smectite and carbonate deposits in Noachian terrain on Mars. However, smectite may have formed under mildly acidic conditions. Abundant smectite formations have been detected as layered deposits hundreds of meters thick in intracrater depositional fans and plains sediments, while no large deposits of carbonates are found. Development of mildly acidic conditions at early Mars might allow formation of smectite but inhibit widespread carbonate precipitation. Little is known regarding the mechanisms of smectite formation from basaltic glass under acidic conditions. The objective of this study was to test a hypothesis that Mars-analogue basaltic glass alters to smectite minerals under acidic conditions (pH 4). The effects of Mg and Fe concentrations and temperature on smectite formation from basaltic glass were evaluated. Phyllosilicate synthesis was performed in batch reactors (Parr acid digestion vessel) under reducing hydrothermal conditions at 200 C and 100 C. Synthetic basaltic glass with a composition similar to that of the Gusev crater rock Adirondack (Ground surface APXS measurement) was used in these experiments. Basaltic glass was prepared by melting and quenching procedures. X-ray diffraction (XRD) analysis indicated that the synthesized glass was composed of olivine, magnetite and X-ray amorphous phase. Samples were prepared by mixing 250 mg Adirondack with 0.1 M acetic acid (final pH 4). In order to study influence of Mg concentration on smectite formation, experiments were performed with addition of 0, 1 and 10 mM MgCl2. After 1, 7 and 14 day incubations the solution composition was analyzed by Inductively Coupled Plasma Mass Spectrometry (ICP-MS) and the altered glass and formed phyllosilicates were examined by XRD analysis. Mineralogical changes were significant in Adirondack incubated with 10 mM MgCl2 at pH 4 and heated at 200 C. X-ray diffraction analysis revealed formation of phyllosilicate during 14 day incubation (Figure 1). Smectite was confirmed as the phyllosilicate after treatments with glycerol and KCl and heating to 550 C. The position of 02l (4.60 A) and 060 (1.54 A) diffraction bands were indicative of trioctahedral smectite such as saponite. Analysis of solution composition demonstrated that aqueous concentration of Mg decreased from 10 mM to approx.4 mM after 7 day incubation likely due to saponite formation. Smectite also formed in Adirondack incubated with 0 mM MgCl2 at pH 4 and heated at 200 C. However, diffraction peak positions of 02l (4.52 A) and 060 (1.51 A) suggested formation of dioctahedral nontronite. The 100degC Mg and Fe(II) treated basaltic glass experiments are ongoing and results will be presented.

Peretyazhko, Tanya↗
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 NTRS2014

Investigation of Spiral Bevel Gear Condition Indicator Validation via AC-29-2C Using Fielded Rotorcraft HUMS Data

This report presents the analysis of gear condition indicator data collected on a helicopter when damage occurred in spiral bevel gears. The purpose of the data analysis was to use existing in-service helicopter HUMS flight data from faulted spiral bevel gears as a Case Study, to better understand the differences between HUMS data response in a helicopter and a component test rig, the NASA Glenn Spiral Bevel Gear Fatigue Rig. The reason spiral bevel gear sets were chosen to demonstrate differences in response between both systems was the availability of the helicopter data and the availability of a test rig that was capable of testing spiral bevel gear sets to failure. The objective of the analysis presented in this paper was to re-process helicopter HUMS data with the same analysis techniques applied to the spiral bevel rig test data. The damage modes experienced in the field were mapped to the failure modes created in the test rig. A total of forty helicopters were evaluated. Twenty helicopters, or tails, experienced damage to the spiral bevel gears in the nose gearbox. Vibration based gear condition indicators data was available before and after replacement. The other twenty tails had no known anomalies in the nose gearbox within the time frame of the datasets. These twenty tails were considered the baseline dataset. The HUMS gear condition indicators evaluated included gear condition indicators (CI) Figure of Merit 4 (FM4), Root Mean Square (RMS) or Diagnostic Algorithm 1 (DA1) and +/- 3 Sideband Index (SI3). Three additional condition indicators, not currently calculated on-board, were calculated from the archived data. These three indicators were +/- 1 Sideband Index (SI1), the DA1 of the difference signal (DiffDA1) and the peak-to-peak of the difference signal (DP2P). Results found the CI DP2P, not currently available in the on-board HUMS, performed the best, responding to varying levels of damage on thirteen of the fourteen helicopters evaluated. Two additional CIs also not in the on-board system, DiffDA1and SI1, also performed well responding to twelve and ten of the fourteen helicopters evaluated respectively. Of the three CIs currently available in the MSPU, DA1, FM4 and SI3, SI3, responded to eight, DA1 responded to six and FM4 responded to four of the fourteen helicopters evaluated. FM4, the poorest performing CI, was not as responsive to damage as the other five CIs. Conversely, when compared to the other two, it was the only CI that responded to damage on two helicopters. CI response could not be correlated to specific failure modes due to limited pictures and subjective descriptions found within the TDA. Flight regime did affect CI response to some gear faults. Due to the range of operating conditions for each regime, more studies are required to determine their sensitivity to regimes.

rotorcraft↗