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Gears with an asymmetric involute gear tooth form were analyzed to determine their bending and contact stresses relative to symmetric involute gear tooth designs, which are representative of helicopter main-drive gears.
A single tooth bending (STB) test procedure has been developed to optimally map gear design parameters. Also, a test program on case-carburized, aerospace standard gears has been conceived and performed in order to appreciate the influence of various technological parameters on fatigue resistance and to draw the curve shape up to the gigacycle region.
Following is a report on the R&D findings regarding remediation of high-value, high-demand spiral bevel gears for the UHâ€“60 helicopter tail rotor drivetrain. As spiral bevel gears for the UHâ€“60 helicopter are in generally High-Demand due to the needs of new aircraft production and the overhaul and repair of aircraft returning from service, acquisition of new spiral bevel gears in support of R&D activities is very challenging. To compensate, an assessment was done of a then-emerging superfinishing method—i.e., the micromachining process (MPP)—as a potential repair technique for spiral bevel gears, as well as a way to enhance their performance and durability. The results are described in this paper.
Oil-out conditions, or conditions in which an aircraft is operating without any oil in its gearbox or transmission, are devastating for an aircraft's hardware. Even the sturdiest gears usually can't last 30 minutes under such conditions before they catastrophically fail, and the whole system usually follows shortly after. That doesn't leave pilots with a whole lot of time to find a suitable location to land in the case of an oil-out emergency.
Designers are constantly searching for ways to reduce rotocraft drive system weight. Reduced weight can increase the payload, performance, or power density of current and future systems. One example of helicopter transmission weight reduction was initiated as part of the United States Army Advanced Rotocraft Transmission program. This example used a split-torque, face-gear configuration concept (Ref. 1). compared to a conventional design with spiral-bevel gears, the split-torque, face-gear design showed substantial weight savings benefits. Also, the use of face gears allows a wide-range of possible configurations with technical and economic benefits (Ref. 2).
In helicopter applications, the two-piece gear is typically joined by welding, bolts, or splines. In the case of the U.S. Army CH-47D Chinook helicopter, a decision was made to eliminate these joints through the use of integral design. Integral shaft spiral bevel gears must be designed such that the shaft does not interfere with gear tooth cutting and grinding. This paper discusses techniques to iterate in the design stage before manufacturing begins.
A computational fluid dynamics (CFD) method is adapted, validated and applied to spinning gear systems with emphasis on predicting windage losses. Several spur gears and a disc are studied. The CFD simulations return good agreement with measured windage power loss.
The design of any gearing system is a difficult, multifaceted process. When the system includes bevel gearing, the process is further complicated by the complex nature of the bevel gears themselves. In most cases, the design is based on an evaluation of the ratio required for the gear set, the overall envelope geometry, and the calculation of bending and contact stresses for the gear set to determine its load capacity. There are, however, a great many other parameters which must be addressed if the resultant gear system is to be truly optimum. A considerable body of data related to the optimal design of bevel gears has been developed by the aerospace gear design community in general and by the helicopter community in particular. This article provides a summary of just a few design guidelines based on these data in an effort to provide some guidance in the design of bevel gearing so that maximum capacity may be obtained. The following factors, which may not normally be considered in the usual design practice, are presented and discussed in outline form: Integrated gear/shaft/bearing systems Effects of rim thickness on gear tooth stresses Resonant response
Studies to evaluate low-noise Formate spiral bevel gears were performed. Experimental tests were conducted on a helicopter transmission test stand...
This paper describes the research and development of the first production gearbox with asymmetric tooth profiles for the TV7-117S turboprop engine. The paper also presents numerical design data related to development of this gearbox.
In a little-known incident, Soviet machinists at Mil Helicopter worked in 1988 and 1989 on a special project to be used against Americans.
Cubic boron nitride (CBN) finishing of carburized gearing has been shown to have certain economic and geometric advantages and, as a result, it has been applied to a wide variety of precision gears in many different applications. In critical applications such as aerospace drive systems, however, any new process must be carefully evaluated before it is used in a production application. Because of the advantages associated with this process, a test program was instituted to evaluate the load capacity of aerospace-quality gears finished by the CBN process as compared to geometrically identical gears finished by conventional grinding processes. This article presents a brief description of the CBN process, its advantages in an aerospace application, and the results of an extensive test program conducted by Boeing Helicopters (BH) aimed at an evaluation of the effects of this process on the scoring, surface durability, and bending fatigue properties of spur gears. In addition, the results of an x-ray diffraction study to determine the surface and subsurface residual stress distributions of both shot-peened and nonshot-peened CBN-ground gears as compared to similar conventionally ground gears are also presented.
Aerospace manufacturing has seen quite a turnaround in the past few years. The world's manufacturers of airplanes, helicopters, missiles, space vehicles and satellites are all extremely busy right now--and that's keeping quite a few gear manufacturers busy as well.
Lego Technics actually just turned 40 last year. Technic kits have always differentiated themselves from their blocky contemporaries with a focus on additional parts such as gears, motors and axles to facilitate motion, and while the window dressing has changed over the years from the bulldozers and helicopters of yesteryear to the newest, coolest sports cars today, that core premise hasn't.
A major source of helicopter cabin noise (which has been measured at over 100 decibels sound pressure level) is the gearbox. Reduction of this noise is a NASA and U.S. Army goal. A requirement for the Army/NASA Advanced Rotorcraft Transmission project was a 10 dB noise reduction compared to current designs.
A common design goal for gears in helicopter or turboprop power transmission is reduced weight. To help meet this goal, some gear designs use thin rims. Rims that are too thin, however, may lead to bending fatigue problems and cracks. The most common methods of gear design and analysis are based on standards published by the American Gear Manufacturers Association. Included in the standards are rating formulas for gear tooth bending to prevent crack initiation (Ref. 1). These standards can include the effect of rim thickness on tooth bending fatigue (Ref 2.). The standards, however, do not indicate the crack propagation path or the remaining life once a crack has started. Fracture mechanics has developed into a useful discipline for predicting strength and life of cracked structures.
Aircraft transmissions for helicopters, turboprops and geared turbofan aircraft require high reliability and provide several thousand hours of operation between overhauls. In addition, They should be lightweight and have very high efficiency to minimize operating costs for the aircraft.
A major source of helicopter cabin noise (which has been measured at over 100 decibels sound pressure level) is the gear box. Reduction of this noise is a NASA and U.S. Army goal.
Spiral-bevel gears, found in many machine tools, automobile rear-axle drives, and helicopter transmissions, are important elements for transmitting power.