technology innovation of power transmission gearing · pdf fileplenary presentation at the...
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Plenary Presentation at the Motion and Power Transmission Conference (MPT2009), Matsushima, Japan, May 2009 TECHNOLOGY INNOVATION OF POWER TRANSMISSION GEARING IN AVIATION
by
Dr. Robert F. Handschuh
Army Research Laboratory, NASA Glenn Research Center Cleveland, Ohio, USA
Overview
An overview of rotary wing evolution and innovations over the last 20 years was presented.
This overview is provided from a drive system perspective. Examples of technology
innovations that have changed and advanced drive systems of rotary wing vehicles will be
provided. These innovations include full 6-axis CNC gear manufacture, face gear development
to aerospace standards, health and usage monitoring, and gear geometry and bearing
improvements. Also, an overview of current state-of-the-art activities being conducted at
NASA Glenn is presented with a short look to fixed and rotary wing aircraft and systems
needed for the future.
https://ntrs.nasa.gov/search.jsp?R=20130013154 2018-05-01T12:42:51+00:00Z
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Technology Innovation of Power Transmission Gearing in Aviation
Dr. Robert F. HandschuhU. S. Army Research LaboratoryVehicle Technology DirectorateNASA Glenn Research Center
Cleveland, Ohio, U.S.A.
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Topics
• Fixed and rotating wing aircraft evolution / innovation– Types of aircraft – Engines– Drive system• Technology innovation - drive system
perspective• Current NASA / GRC research
– Structures and Materials Division– Tribology & Mechanical Components Branch
• Future, what is next ?????• Questions?
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NASA Aeronautics Centers
AmesResearch
Center
GlennResearch
Center
LangleyResearch
Center
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NASA Glenn Research Center
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AeroshellsTPS; Cooled strs.Cryogenic tanksNacellesCombustorsEngine fan systemMechanismsOil-Free enginesInjectorsHigh-power motorsSpace lubricantsProtective CoatingsSensorsThermoelectrics
Surface mobility systemsNozzlesIn-space & on-surface modulesRotor discs and systemsTurbine vanesEnergy absorbing systemsMechanical drive systemsHuman health systemsThrustersBearings and flywheelsSolid oxide fuel cells, batteriesHigh temp. and cryogenic sealsPorous membranesBN nanotubes
Probabilistic methods Matl. and strl. Concepts Design technologyMechanical power transfer Health prognostics Experimental methodsImpact dynamics Blast mechanics Measurement technologyStructural mechanics Structural dynamics AeroelasticityMaterial modeling Joining technology Durability and lifeMaterial characterization Failure and damage growth Fatigue and fractureFunctional materials Processing technologies High temp. and cryo sealsMetallic alloys Shape memory alloys Ceramic materials Computational materials Protective coatings Multifunctional MaterialsSurface science Extreme environment effects Lubricant chemistryMaterials science High temperature chemistry Friction and wear
Materials and Structures Division Capabilities for Aeronautics and Exploration Systems
Advanced Drive Systems
Advanced Thermal Barrier Seals
Actively Controlled
Nozzle
Oil-Free Foil Gas Bearings
Energy Absorbing Systems
Engine Components
Propulsion and Power System Components
Cryo Tanks
NanotubesGRCop Thrust Chamber
Materials and Structures Division
Core R&T Capabilities
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Technical Innovation
• Airplane / rotorcraft evolution
• Engines (piston to gas turbine to ….. )
• Drive systems
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Civil Aircraft Evolution
• Douglas DC-3• Boeing 707• Boeing 737,747
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Civil Aircraft Evolution
• Airbus 380• Boeing 787
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Helicopter Evolution
• Piston engine RC’s (1950’s)• Turbo – shaft powered RC’s (Huey, OH-58…)• Multi-engine RC’s CH-46, UH-60,…• Civilian use for medivac, border patrol, law
enforcement, television news, sightseeing…….
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Helicopter Evolution
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Helicopter Evolution
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Tiltrotor Evolution
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Engine Innovation• Piston engines (radial)• Turbo-jet engine• Turbo-fan / turbo-
shaft engines
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Engine Innovation
• High By-pass Turbofan engines
• Geared turbo-fan…
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Drive “System” Evolution
• Higher speed engines• Multi-engine main drive systems• Advanced concepts
– Non-traditional arrangements & gear types– Split torque – multipath – Advanced manufacture– Advanced analysis– Advanced testing
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Example Rotorcraft Transmission
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Drive System Stress Analysis
• Beam models• AGMA, ISO, DIN and other methods• FEA – assumed loading, single gear mesh• FEA – tooth contact, multi-component contact, …..
Leads to better understanding of what is found in practice.
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Drive System Vibration / Noise
• Simple dynamic models – rigid body – lumped mass
• Profile modification effects, helical effects,…• More complex – multi-element analysis• Shafting – bearings – damping• Complete end-to-end dynamic simulation
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Gear Geometry
• Involute gear geometry• Extrapolation to other non-involute gearing• Computer kinematic manufacture process for surface
geometry – details of surface only graphical • Gear geometry analysis – Dr. Faydor Litvin,
kinematics of manufacture, equation of meshing, principal surface orientation, exact surface information
• Techniques applied to many types of gear systems
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Gear Manufacturing
• Manual machine tools• Gear geometry • Coordinate measuring machinery• Combination of gear measurement –
manufacture machine tool settings• Full CNC manufacture with feedback
from manufactured parts
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Gear Performance
• Gear meshing efficiency – sliding & rolling losses: NASA - Anderson & Lowenthal models
• High speed gearing requirements• Gear windage – empirical models• Gear windage – CFD analysis & high speed
experimental capability
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Examples of TechnologyInnovation of Power
Transmission Gearing in Aviation
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Spiral Bevel Gear Manufacturing
Gleason WorksPhoenix Full CNC
Spiral Bevel Gear GrindingGleason Works
463 MachineManual
Gleason Works463 CNC Machine
Partial CNC
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Technology Innovation – Face Gears
Advanced Rotorcraft Transmission Program
Face Gear Geometry Development
Face Gear Grinding Development
Face Gear Testing - Fatigue
Face Gear – Aircraft Application
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Face Gears
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Face Gears
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Condition Based Maintenance
Lubricant Analysis
Chip Detectors
Vibration Sensing
Metallic Debris Monitors
Vibration Algorithms
Fuzzy Logic &Data Fusion used forImproved condition
determination
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Vibration Algorithm Development
Time / Cycles
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Condition Based Experiment
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Spiral Bevel Gear Development
Gleason Works Geometry – Machine Settings
Improved Contact Conditions,Fillet Geometry with
Litvin Machine Tool Settings
Lower Cost Formate Designwith
Low Noise and Stress
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Low-Noise Formate Spiral-Bevel Gears
HeelToe
20
19
18
1615
1413
12
17
11
3
2
1
98
5
10
4
76
Results: Decreased noise, vibration, stresses
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Gear Performance - Superfinishing
speed (rpm)
0 1000 2000 3000 4000 5000
powerloss(W)
0
100
200
300
400
groundsuperfinished
1
3
2
4Scoring Load Increased
sliding speed (m/s)
6 9 12 15 18 21 24
scoringload(N)
0
1000
2000
3000
4000
groundsuperfinished
1 µm
100 µm
Surface Finish Improved
ground
millions of stress cycles
2 6 20 100 600
percentspecimens
failed
1
5
20
50
90
99 groundsuperfinished suspended
(x3)
(x7)
superfinished
Surface Fatigue Life Increased
Power Loss Reduced
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Transmission System
carrieroutput
input
planetarymesh
spiral-bevelmesh
spiral-bevelpinion
sun gear
spiral-bevelgear
planetgear
ring gear
Technology Innovation has resulted in the transmission system design power going from 300 hp to over 600 hp
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Current Activities of Tribology and Mechanical
Components Branch at NASA Glenn Research Center in Support of
Future Innovation
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Tribology & Mechanical Components Branch
Branch Organization:
Oil-Free Turbomachinery - Air Bearings for Aeronautic and
Space Applications
Space Mechanisms & Lubrication – Basic Research for
Space Applications
Aerospace Seals – Seals for turbine engine and aerospace /
space structures
Aero Drive Systems – Power Transfer (Gears, Bearings, etc.)
for Aeronautic & Space Applications
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Tribology & Mechanical Components Branch
Heat Shield Interface Seal
Docking Seal
Aerospace Seals Research
• Space habitat seals for extreme environments• Structural / thermal protection seals• Non-contacting turbine seals
• Accelerated space lubricant life testing under vacuum• New mechanism concepts for planetary environment• New space lubricant development• Terramechanics modeling & testing for efficient wheels
Space Mechanisms & Lubrication
Aero Drive Systems
• Gear fatigue research• High speed gear lubrication• Drive system diagnostics • Fatigue crack modeling• Dynamic mechanical components• Rotorcraft transmission systems • Advanced rolling element and wave bearing technologies
Oil-Free Turbomachinery
• Aero / Space application• World-leading bearing experts• Advanced modeling methods• Foil bearing predictive design
From basic research to application
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Oil-Free Turbomachinery
Foil air bearings
X
Y
Z X
Y
Z
CAD
For cryogenic to 800C sliding contacts
PM304 bushings for industrial furnaces
and valves
PS304
Oil-Free enabling technologies
TGIR Award for Level I Milestone:“Core Hot Bearing Tests” (OFTET)
?
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Space Tribology & Materials
SPIRAL ORBIT TRIBOMETERAccelerated Lubricant Life
Testing Under RealisticConditions
VACUUM 4-BALLAccelerated Bulk Property
Testing of Lubricants
BEARING RIGFull Scale
Bearing Tests
Other Facilities:•Vapor Pressure of Fluids
•Radiation Damage of Polymers
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NASA GRC Seal Research
NASA GRC Seal Research:– Shuttle main landing gear door environmental seals– Thermal barrier (braided carbon fiber rope) for
nozzle joints of Shuttle and Atlas V SRM’s
Shuttle MLG door seals
Thermal barrier for Shuttle and Atlas V SRM nozzle joints
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Seal Test Facilities
Exploration Systems Seals Lab (B5, C-9/SE-14)
Load frame
Laser extensometer
Actuator
3000 °F furnace
Load cells &
alignment fixture
Test fixturing
Structural Seals Lab (B5, SW-17)
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Drive Systems Team
Current Research Activities
(Future Innovation)
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Drive System Test Facilities
Spur Gear Fatigue Test Rigs Spiral Bevel / Face Gear Test Facilities Gear Noise / Dynamics Test Facility
Split Torque Test Facility OH-58 Transmission Test Facility High Speed Helical Gear Train Facility
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Drive System Analytical Capabilities
Finite Element Based Structural - Thermal Planetary Gear Dynamics
Fracture Mechanics - BEM
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High Speed Gearing - Windage
Input Shaft Speed (RPM)6000 8000 10000 12000 14000
Win
dage
Pow
er L
oss
(hp)
0
10
20
30
40
50
60
70
Dawson Model 1% LubeDawson Model 0.75% LubeDaswson Model 0.5% LubeDawson Model 0.25% LubeDawson Model - No Lube
Input Torque (in*lb)8000 10000 12000 14000 16000 18000 20000
Pred
icte
d Po
wer
Los
s (h
p)
0
20
40
60
80
100
WIndage Losses
Gear Meshing Losses
Bearing Losses
Gearbox Power (hp)1000 2000 3000 4000 5000
Effic
ienc
y (%
)
94
95
96
97
98
99
Experimental Results 12500 RPMExperimental Results 15000 RPMAnalytical Prediction 12500 RPMAnalytical Prediction 15000 RPM
PWindage = C3C'ρN 2.85D4.7v 0.15λ
TotalLosses
(hp)
Efficiency(%)
WindagePowerLoss(hp)
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Condition Based Maintenance
Objectives: Increase reliability and decrease false alarms for mechanical component diagnostics. Demonstrate integration of oil debris and vibration based damage detection techniques results in improved capability.
Approach:Instrument and monitor all GRC gear fatigue test facilities and work with other govt. agencies, university, and industry
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Vibration Techniques (FM4,NA4) and Oil
Debris
Output of Fuzzy Logic Model
Condition Based Maintenance
00.10.20.30.40.50.60.70.80.9
1
0 500 1000 1500 2000 2500 3000 3500
Reading Number
Mod
el O
utpu
t
Normal
Inspect
Damage
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Wave Bearing Technology
• Improved stability and cooling• Ability to tailor stiffness and damping• Use of hard sleeves
Test FacilityBearing Concept
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Fracture Toughness
Ferrium C69 AISI 9310
Surface Fatigue ResultsGearMaterial
Number of
failures
Number of tests
completed
Median life(million cycles)
AMS 6308B[Ref. 10]
15 21 134
AISI 9310[Ref. 13]
25 33 200
Ferrium C69[present study]
5 10 361
Advanced Gear Material
• Excellent Contact Fatigue• Poor Fracture Toughness
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Space Mechanism Wear
ew p ofilworn pro ile
Dither Damage Assessment
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Low Cycle Bending Fatigue
Cycles1e+0 1e+1 1e+2 1e+3 1e+4 1e+5
Line
ar E
last
ic N
omin
alB
endi
ng S
tres
s (K
SI)
200
250
300
350
400
450
500
550
600
650
Bending
Stress
Index
(ksi)
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Where are we headed in aviation?
(Still need drive system technology to make configurations possible)
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Future Aircraft
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Tri-Fan Configuration
Blended Wing Propulsion Schematic
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Civil Tiltrotor Drive System Configuration
Hover Ratio 131.4 : 1 Forward Flight Ratio 243.6 : 1
To Mid-Wing Gearbox
Tilt AxisGearbox
Combiner GearboxReductionGearbox
Variable / Multi-Speed Gearbox
Rotor
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In-Line Two Speed Drive System
Input
Output
Star Planetary
Wet / Dry Clutch
Over-Running Clutch
High Speed Operation: Wet / Dry Clutch engaged, Over-Running Clutch over-runningLow Speed Operation: Wet / Dry Clutch disengaged, Over-Running Clutch driving
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What’s Next?
Drive system R&D – still much to be done
Full System modeling & simulation
On-condition maintenance
Improved efficiency of drive systems
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Questions?
Thanks for your attention!