Engineering topics

Jessie, Nathan

Publications and source records attributed to Jessie, Nathan.

3 records

NASA NTRS2019

Static Torsion Testing and Modeling of a Variable Thickness Hybrid Composite Bull Gear

Torsional strength of a variable thickness hybrid gear web was measured by performing static testing on the part in a large torsion test frame. The outer rim of the hybrid gear web was fixed to the bottom of the test frame and loading was applied to the web through a shaft. The test setup included the installation of digital image correlation (DIC) systems to obtain deformation and strain measurements from the surfaces of the hybrid gear web and the mechanical test equipment to ensure reliability of the test. The results indicated that the variable thickness hybrid gear web achieved approximately twice the torsional strength compared to that of previous hybrid gear designs. The DIC analysis showed significantly more straining of the loading shaft than the actual test article. Additionally, the results demonstrated the importance and affect that the metallic, lobed interlock features had on the principal strain and out-of-plane displacement fields. The analysis revealed that the fixed outer rim was in fact rotating and a rigid body motion compensation (RBMC) function was computed to determine the actual rotation of the hub and composite web relative to the outer rim. Modeling simulations were performed for the variable thickness hybrid gear web and correlated well with the RBMC rotational deformation seen in the DIC analysis. In addition to benchmarking the load capacity of the hybrid gear web, measuring its strength is useful information to define the parameters needed for dynamic, endurance, and other testing of the part.

Johnston, Joel P.↗

NASA NTRS2015

Braided Composite Technologies for Rotorcraft Structures

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.

Jessie, Nathan↗

NASA NTRS2014

Braided Composite Technologies for Rotorcraft Structures

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.

Jessie, Nathan↗