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Bending stress reduced by improving tooth-fillet design. Using optimized gear-cutter design technology, gear designer reduces bending stresses by up to 20 percent. Reduction in bending stress is result of improved geometry of tooth fillet, which, in turn, results in significant improvement in horsepower-per-pound ratio. Gears run quieter and smoother than spur-gear system.
Magnetic gears present significant structural design challenges, because metallic/electrically conductive structures are highly undesirable as they would lead to significant efficiency reductions. Additionally, most non-electrically conductive structural materials have low thermal conductivity, which makes cooling the gear difficult. These limitations are of particular significant in magnetic gear's modulator structures. NASA Glenn has shown that pole pieces on the order of 1 to 2 mm thick optimize magnetic gears specific torque. These thin pole pieces however see very large magnetic forces and modulator structural limitations prevent the use of magnetically optimum pole pieces. The best solution to this issue to date has been the use of carbon fiber retaining rings on the external surface of the modulator, however this solution increases ring modulator airgap, resulting in a torque reduction from the optimum design. The pole pieces are also the largest sources of losses in magnetic gears. Because the modulator is nestled between the ring and sun gear extraction of this heat is a difficult problem and the modulator structure has to be designed to dissipate this heat load. In the presentation I will present the design of NASA Glenn's 4th magnetic gear's modulator in detail that uses a combination of 3D fiber reinforced nylon, IM7 carbon fiber, and pitch base cn80 fiber to close both structurally and thermally.
A preliminary design study has indicated that advanced composite helicopter airframe structures can provide significant system cost advantages in the 1980's. A seven percent increase in productivity and a five percent reduction in life cycle cost are projected. Due to their complexity, landing gear structures do not substantially benefit from the use of advanced composites. The most successful concept was found to be all-molded composite modular panels, which provide integral skin/stringer and frame subassemblies. These subassemblies significantly reduce the number of parts relative to present construction. The subassemblies are mechanically jointed together for economical, rapid final assembly and permit field replacement in the event of major damage.
Space-compatible cryogenic valves are now required to operate between room and liquid helium temperatures. A remotely controllable cryogenic valve is described, which is made of bellows-type stainless steel and is operated by a miniature dc motor with integral gearset (485:1) at a nominal voltage of 28 Vdc. The power transmission provides a further reduction of 7.2:1 to give an overall gear ratio of nearly 3500:1, assuring reliability of operation at low temperatures. Valve performance (leak rate) data are presented at LN2, LHe, and SfHe temperatures at delivered torques of 18, 27, 31, and 35 N-m. At a closing torque of 31 N-m, a leak rate of 0.028 scc/sec was achieved at 2 K, while at a torque of 18 N-m the leak rate at 300 K was less than 3 x 10 to the -9th scc/sec.
The helicopter has evolved into a highly valuable air mobile vehicle for both military and civilian needs. The helicopter transmission requires advanced studies to develop a technology base for future rotorcraft advances. A joint helicopter transmission research program between the NASA Lewis Research Center and the U.S. Army Aviation Systems Command has existed since 1970. Program goals are to reduce weight and noise and to increase life and reliability. The current experimental activities at Lewis consist of full-scale helicopter transmission testing, a base effort in gearing technology, and a future effort in noise reduction technology. The experimental facilities at Lewis for helicopter transmission testing are described. A description of each of the rigs is presented along with some significant results and near-term plans.
The present conference discusses plasma-assisted surface coating/modification processes, the applications to date of ion nitriding, the effects of nitrogen on metal surfaces, ion nitriding mechanisms in Cr, Al and Cr + Al-containing 1040 steel, ion nitriding of Al and its alloys, life enhancement for forging dies, novel anode plasma nitriding developments, and a comparative study of the pulsed and dc ion-nitriding behavior in specimens with blind holes. Also discussed are the influence of heating method on ion nitriding, surface hardening of marage steels by ion nitriding without core hardness reduction, plasma nitriding of nodular cast iron sput gears, NbN composites for superconductors, the carburization of tungsten in a glow discharge methane plasma, economic considerations concerning plasma nitriding, and the corrosion properties obtained by ion nitriding.
A method to design sidestick controllers for general aviation aircraft with reversible flight controls is proposed. The use of a sidestick in this type of flight vehicle generally increases the stick forces required for maneuvering; this is due to a reduction in the moment arm of application of the force. In the present study, the reduction of stick forces is achieved by incorporating geared tabs in the control-surface design. A complete analysis using the rigid-body aircraft longitudinal equations of motion and stick-force equation in coupled form is carried out. Lateral stick forces are predicted by solving the single-degree-of-freedom roll approximation and aileron stick-force equations. Data are presented for configurations with various tab areas and a wide range of gearing ratios. The results indicate that the method can be used successfully for geared-tab design and stick-force prediction. It is shown that gearing-ratio selection is critical but that tab area does not have a significant impact on the magnitude of stick forces and stick force to stick deflection gradients.
In this report, we propose a new geometry for low-noise, increased-strength helical gears of the Novikov-Wildhaber type. Contact stresses are reduced as a result of their convex-concave gear tooth surfaces. The gear tooth surfaces are crowned in the profile direction to localize bearing contact and in the longitudinal direction to obtain a parabolic function of transmission errors. Such a function results in the reduction of noise and vibrations. Methods for the generation of the proposed gear tooth surfaces by grinding and hobbing are considered, and a tooth contact analysis (TCA) computer program to simulate meshing and contact is applied. The report also investigates the influence of misalignment on transmission errors and shift of bearing contact. Numerical examples to illustrate the developed approaches are proposed. The proposed geometry was patented by Ford/UIC (Serial Number 09-340-824, pending) on June 28, 1999.
In this paper, we present steady aerodynamic measurements for an 18% scale model of a Gulfstream air-craft. The high fidelity and highly-instrumented semi-span model was developed to perform detailed aeroacoustic studies of airframe noise associated with main landing gear/flap components and gear-flap interaction noise, as well as to evaluate novel noise reduction concepts. The aeroacoustic tests, being conducted in the NASA Langley Research Center 14- by 22-Foot Subsonic Tunnel, are split into two entries. The first entry, completed November 2010, was entirely devoted to the detailed mapping of the aerodynamic characteristics of the fabricated model. Flap deflections of 39?, 20?, and 0? with the main landing gear on and off were tested at Mach numbers of 0.16, 0.20, and 0.24. Additionally, for each flap deflection, the model was tested with the tunnel both in the closed-wall and open-wall (jet) modes. During this first entry, global forces (lift and drag) and extensive steady and unsteady surface pressure measurements were obtained. Preliminary analysis of the measured forces indicates that lift, drag, and stall characteristics compare favorably with Gulfstream?s high Reynolds number flight data. The favorable comparison between wind-tunnel and flight data allows the semi-span model to be used as a test bed for developing/evaluating airframe noise reduction concepts under a relevant environment. Moreover, initial comparison of the aerodynamic measurements obtained with the tunnel in the closed- and open-wall configurations shows similar aerodynamic behavior. This permits the acoustic and off-surface flow measurements, planned for the second entry, to be conducted with the tunnel in the open-jet mode.
Over the 70-year evolution of the helicopter, man's understanding of vibration control has greatly increased. However, in spite of the increased performance, the extent of helicopter vibration problems has not significantly diminished. Crew vibration and noise remains important factors in the design of all current helicopters. With more complex and critical demands being placed on aircrews, it is essential that vibration and noise not impair their performance. A major source of helicopter cabin noise (which has been measured at a sound pressure level of over 100 dB) is the gearbox. Reduction of this noise has been a goal of NASA and the U.S. Army. Gear mesh noise is typically in the frequency range of 1000 to 3000 Hz, a range important for speech. A requirement for U.S. Army/NASA Advanced Rotorcraft Transmission project has been a 10-dB reduction compared to current designs. A combined analytical/experimental effort has been underway, since the end of the 80's, to study effects of design parameters on noise production. The noise generated by the gear mesh can be transmitted to the surrounding media through the bearings that support the gear shaft. Therefore, the use of fluid film bearings instead of rolling element bearings could reduce the transmission noise by 10 dB. In addition, the fluid film bearings that support the gear shaft can change the dynamics of the gear assembly by providing damping to the system and by being softer than rolling element bearings. Wave bearings can attenuate, and filter, the noise generated by a machine component due to the dynamic stiffness and damping coefficients. The attenuation ratio could be as large as 35-40 dB. The noise components at higher frequencies than a synchronous frequency can be almost eliminated.
In this paper, we present unsteady surface pressure measurements for an 18%-scale, semi-span Gulfstream aircraft model. This high-fidelity model is being used to perform detailed studies of airframe noise associated with main landing gear, flap components, and gear-flap interaction noise, as well as to evaluate novel noise reduction concepts. The aerodynamic segment of the tests, conducted in the NASA Langley Research Center 14- by 22-Foot Subsonic Tunnel, was completed in November 2010. To discern the characteristics of the surface pressure fluctuations in the vicinity of the prominent noise sources, unsteady sensors were installed on the inboard and outboard flap edges, and on the main gear wheels, struts, and door. Various configurations were tested, including flap deflections of 0?, 20?, and 39?, with and without the main landing gear. The majority of unsteady surface pressure measurements were acquired for the nominal landing configuration where the main gear was deployed and the flap was deflected 39?. To assess the Mach number variation of the surface pressure amplitudes, measurements were obtained at Mach numbers of 0.16, 0.20, and 0.24. Comparison of the unsteady surface pressures with the main gear on and off shows significant interaction between the gear wake and the inboard flap edge, resulting in higher amplitude fluctuations when the gear is present.
The development of Vertical Take-off and Landing (VTOL) vehicles for the Urban Air Mobility (UAM) markets presents a need for light weight vehicle structures with effective occupant protection capabilities. The National Aeronautics and Space Administration (NASA) has been working to fill that need, recently developing a cadre of concept vehicles to help characterize UAM design feasibility. This paper describes a study, using these concept vehicles, to evaluate the use of advanced composite structure and energy attenuating designs in the UAM vehicle design space. A finite element model (FEM) of a single passenger quadrotor concept vehicle was developed in LS-Dyna® and simulated under nominal and off-nominal vertical impact conditions. A variety of energy attenuating design mechanisms were implemented within this model to quantify their effectiveness in improving occupant safety. The use of carbon composites in both the energy attenuation mechanisms and vehicle structure was evaluated. The results of this study found significant reduction in occupant injury risk with the implementation of energy absorbing composite crush tubes and landing gear within the vehicle design. Additionally the use of a carbon fiber as a structural material was found to provide significant weight reduction while maintaining similar occupant loads to that predicted with an aluminum structure. This work provides a preliminary evaluation of design mechanisms and materials that may be used to optimize occupant protection capabilities within the UAM market.
Two concepts in power transmission gear design are proposed which provide a potential for large noise reduction and for improving weight to payload ratio due to use of advanced fiber reinforced and ceramic materials. These concepts are briefly discussed. Since both concepts use ultrathin layered rubber-metal laminates for accommodating limited travel displacements, properties of the laminates, such as their compressive strength, compressive and shear moduli were studied. Extensive testing and computational analysis were performed on the first concept gears (laminate coated conformal gears). Design and testing of the second conceptual design (composite gear with separation of sliding and rolling motions) are specifically described.
The authors have extended the application of double circular-arc helical gears for internal gear drives. The geometry of the pinion and gear tooth surfaces has been determined. The influence of errors of alignment on the transmission errors and the shift of the bearing contact have been investigated. Application of a predesigned parabolic function for the reduction of transmission errors was proposed. Methods of grinding of the pinion-gear tooth surfaces by a disk-shaped tool and a grinding worm were proposed.
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.
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.
A&P Technology has developed a braided material approach for fabricating lightweight, high-strength hybrid gears for aerospace drive systems. The conventional metallic web was replaced with a composite element made from A&P's quasi-isotropic braid. The 0deg, plus or minus 60 deg braid architecture was chosen so that inplane stiffness properties and strength would be nearly equal in all directions. The test results from the Phase I Small Spur Gear program demonstrated satisfactory endurance and strength while providing a 20 percent weight savings. (Greater weight savings is anticipated with structural optimization.) The hybrid gears were subjected to a proof-of-concept test of 1 billion cycles in a gearbox at 10,000 revolutions per minute and 490 in-lb torque with no detectable damage to the gears. After this test the maximum torque capability was also tested, and the static strength capability of the gears was 7x the maximum operating condition. Additional proof-of-concept tests are in progress using a higher oil temperature, and a loss-of-oil test is planned. The success of Phase I led to a Phase II program to develop, fabricate, and optimize full-scale gears, specifically Bull Gears. The design of these Bull Gears will be refined using topology optimization, and the full-scale Bull Gears will be tested in a full-scale gear rig. The testing will quantify benefits of weight savings, as well as noise and vibration reduction. The expectation is that vibration and noise will be reduced through the introduction of composite material in the vibration transmission path between the contacting gear teeth and the shaft-and-bearing system.
A&P Technology has developed a braided material approach for fabricating lightweight, high-strength hybrid gears for aerospace drive systems. The conventional metallic web was replaced with a composite element made from A&P's quasi-isotropic braid. The 0deg, +/-60deg braid architecture was chosen so that inplane stiffness properties and strength would be nearly equal in all directions. The test results from the Phase I Small Spur Gear program demonstrated satisfactory endurance and strength while providing a 20 percent weight savings. (Greater weight savings is anticipated with structural optimization.) The hybrid gears were subjected to a proof-of-concept test of 1 billion cycles in a gearbox at 10,000 revolutions per minute and 490 in-lb torque with no detectable damage to the gears. After this test the maximum torque capability was also tested, and the static strength capability of the gears was 7x the maximum operating condition. Additional proof-of-concept tests are in progress using a higher oil temperature, and a loss-of-oil test is planned. The success of Phase I led to a Phase II program to develop, fabricate, and optimize full-scale gears, specifically Bull Gears. The design of these Bull Gears will be refined using topology optimization, and the full-scale Bull Gears will be tested in a full-scale gear rig. The testing will quantify benefits of weight savings, as well as noise and vibration reduction. The expectation is that vibration and noise will be reduced through the introduction of composite material in the vibration transmission path between the contacting gear teeth and the shaft-and-bearing system.