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Lewicki, David G.

Publications and source records attributed to Lewicki, David G..

At least 19 records

Advanced Face Gear Surface Durability Evaluations

The surface durability life of helical face gears and isotropic super-finished (ISF) face gears was investigated. Experimental fatigue tests were performed at the NASA Glenn Research Center. Endurance tests were performed on 10 sets of helical face gears in mesh with tapered involute helical pinions, and 10 sets of ISF-enhanced straight face gears in mesh with tapered involute spur pinions. The results were compared to previous tests on straight face gears. The life of the ISF configuration was slightly less than that of previous tests on straight face gears. The life of the ISF configuration was slightly greater than that of the helical configuration.

fatigue

Testing of Two-Speed Transmission Configurations for Use in Rotorcraft

Large civil tiltrotors have been identified to replace regional airliners over medium ranges to alleviate next-generation air traffic. Variable rotor speed for these vehicles is required for efficient high-speed operation. Two-speed drive system research has been performed to support these advanced rotorcraft applications. Experimental tests were performed on two promising two-speed transmission configurations. The offset compound gear (OCG) transmission and the dual star/idler (DSI) planetary transmission were tested in the NASA Glenn Research Center variable-speed transmission test facility. Both configurations were inline devices with concentric input and output shafts and designed to provide 1:1 and 2:1 output speed reduction ratios. Both were designed for 200 hp and 15,000 rpm input speed and had a dry shift clutch configuration. Shift tests were performed on the transmissions at input speeds of 5,000, 8,000, 10,000, 12,500, and 15,000 rpm. Both the OCG and DSI configurations successfully perform speed shifts at full rated 15,000 rpm input speed. The transient shifting behavior of the OCG and DSI configurations were very similar. The shift clutch had more of an effect on shifting dynamics than the reduction gearing configuration itself since the same shift clutch was used in both configurations. For both OCG and DSI configurations, low-to-high speed shifts were limited in applied torque levels in order to prevent overloads on the transmission due to transient torque spikes. It is believed that the relative lack of appreciable slippage of the dry shifting clutch at operating conditions and pressure profiles tested was a major cause of the transient torque spikes. For the low-to-high speed shifts, the output speed ramp-up time slightly decreased and the peak out torque slightly increased as the clutch pressure ramp-down rate increased. This was caused by slightly less clutch slippage as the clutch pressure ramp-down rate increased.

Lewicki, David G.

Concepts for Multi-Speed Rotorcraft Drive System - Status of Design and Testing at NASA GRC

In several studies and on-going developments for advanced rotorcraft, the need for variable multi-speed capable rotors has been raised. Speed changes of up to 50 have been proposed for future rotorcraft to improve vehicle performance. A rotor speed change during operation not only requires a rotor that can perform effectively over the operating speedload range, but also requires a propulsion system possessing these same capabilities. A study was completed investigating possible drive system arrangements that can accommodate up to a 50 speed change. Key drivers were identified from which simplicity and weight were judged as central. This paper presents the current status of two gear train concepts coupled with the first of two clutch types developed and tested thus far with focus on design lessons learned and areas requiring development. Also, a third concept is presented, a dual input planetary differential as leveraged from a simple planetary with fixed carrier.

transmission

Concepts for Multi-Speed Rotorcraft Drive System - Status of Design and Testing at NASA GRC

In several studies and on-going developments for advanced rotorcraft, the need for variable/multi-speed capable rotors has been raised. Speed changes of up to 50 percent have been proposed for future rotorcraft to improve vehicle performance. A rotor speed change during operation not only requires a rotor that can perform effectively over the operating speed/load range, but also requires a propulsion system possessing these same capabilities. A study was completed investigating possible drive system arrangements that can accommodate up to a 50 percent speed change. Key drivers were identified from which simplicity and weight were judged as central. This paper presents the current status of two gear train concepts coupled with the first of two clutch types developed and tested thus far with focus on design lessons learned and areas requiring development. Also, a third concept is presented, a dual input planetary differential as leveraged from a simple planetary with fixed carrier.

variable-speed

Offset Compound Gear Inline Two-Speed Drive

A two-speed transmission having an input shaft and an output shaft, the transmission being capable of transitioning between fixed ratios, the high-range ratio being direct 1:1 and the low-range ratio being about 2:1. The transmission is a simple lightweight, yet robust, configuration utilizing only two gear meshes, being comprised of an input gear, a cluster gear, and an output gear. The transmission is controlled with a clutch and a sprag and with the input and output shafts turning in the same direction.

Stevens, Mark A.

Offset Compound Gear Inline Two-Speed Drive

A two-speed transmission having an input shaft and an output shaft, the transmission being capable of transitioning between fixed ratios, the high-range ratio being direct 1:1 and the low-range ratio being about 2:1. The transmission is a simple lightweight, yet robust, configuration utilizing only two gear meshes, being comprised of an input gear, a cluster gear, and an output gear. The transmission is controlled with a clutch and a sprag and with the input and output shafts turning in the same direction.

Stevens, Mark A.

Variable-Speed Simulation of a Dual-Clutch Gearbox Tiltrotor Driveline

This investigation explores the variable-speed operation and shift response of a prototypical two-speed dual-clutch transmission tiltrotor driveline in forward flight. Here, a Comprehensive Variable-Speed Rotorcraft Propulsion System Modeling (CVSRPM) tool developed under a NASA funded NRA program is utilized to simulate the drive system dynamics. In this study, a sequential shifting control strategy is analyzed under a steady forward cruise condition. This investigation attempts to build upon previous variable-speed rotorcraft propulsion studies by 1) including a fully nonlinear transient gas-turbine engine model, 2) including clutch stick-slip friction effects, 3) including shaft flexibility, 4) incorporating a basic flight dynamics model to account for interactions with the flight control system. Through exploring the interactions between the various subsystems, this analysis provides important insights into the continuing development of variable-speed rotorcraft propulsion systems.

DeSmidt, Hans

Helical Face Gear Development Under the Enhanced Rotorcraft Drive System Program

U.S. Army goals for the Enhanced Rotorcraft Drive System Program are to achieve a 40 percent increase in horsepower to weight ratio, a 15 dB reduction in drive system generated noise, 30 percent reduction in drive system operating, support, and acquisition cost, and 75 percent automatic detection of critical mechanical component failures. Boeing s technology transition goals are that the operational endurance level of the helical face gearing and related split-torque designs be validated to a TRL 6, and that analytical and manufacturing tools be validated. Helical face gear technology is being developed in this project to augment, and transition into, a Boeing AH-64 Block III split-torque face gear main transmission stage, to yield increased power density and reduced noise. To date, helical face gear grinding development on Northstar s new face gear grinding machine and pattern-development tests at the NASA Glenn/U.S. Army Research Laboratory have been completed and are described.

Heath, Gregory F.

Fiber Optic Strain Sensor for Planetary Gear Diagnostics

This paper presents a new sensing approach for helicopter damage detection in the planetary stage of a helicopter transmission based on a fiber optic strain sensor array. Complete helicopter transmission damage detection has proven itself a difficult task due to the complex geometry of the planetary reduction stage. The crowded and complex nature of the gearbox interior does not allow for attachment of sensors within the rotating frame. Hence, traditional vibration-based diagnostics are instead based on measurements from externally mounted sensors, typically accelerometers, fixed to the gearbox exterior. However, this type of sensor is susceptible to a number of external disturbances that can corrupt the data, leading to false positives or missed detection of potentially catastrophic faults. Fiber optic strain sensors represent an appealing alternative to the accelerometer. Their small size and multiplexibility allows for potentially greater sensing resolution and accuracy, as well as redundancy, when employed as an array of sensors. The work presented in this paper is focused on the detection of gear damage in the planetary stage of a helicopter transmission using a fiber optic strain sensor band. The sensor band includes an array of 13 strain sensors, and is mounted on the ring gear of a Bell Helicopter OH-58C transmission. Data collected from the sensor array is compared to accelerometer data, and the damage detection results are presented

Kiddy, Jason S.

Planetary Gearbox Fault Detection Using Vibration Separation Techniques

Studies were performed to demonstrate the capability to detect planetary gear and bearing faults in helicopter main-rotor transmissions. The work supported the Operations Support and Sustainment (OSST) program with the U.S. Army Aviation Applied Technology Directorate (AATD) and Bell Helicopter Textron. Vibration data from the OH-58C planetary system were collected on a healthy transmission as well as with various seeded-fault components. Planetary fault detection algorithms were used with the collected data to evaluate fault detection effectiveness. Planet gear tooth cracks and spalls were detectable using the vibration separation techniques. Sun gear tooth cracks were not discernibly detectable from the vibration separation process. Sun gear tooth spall defects were detectable. Ring gear tooth cracks were only clearly detectable by accelerometers located near the crack location or directly across from the crack. Enveloping provided an effective method for planet bearing inner- and outer-race spalling fault detection.

Lewicki, David G.

Seeding Cracks Using a Fatigue Tester for Accelerated Gear Tooth Breaking

This report describes fatigue-induced seeded cracks in spur gears and compares them to cracks created using a more traditional seeding method, notching. Finite element analysis (FEA) compares the effective compliance of a cracked tooth to the effective compliance of a notched tooth where the crack and the notch are of the same depth. In this analysis, cracks are propagated to the desired depth using FRANC2D and effective compliances are computed in ANSYS. A compliance-based feature for detecting cracks on the fatigue tester is described. The initiated cracks are examined using both nondestructive and destructive methods. The destructive examination reveals variability in the shape of crack surfaces.

Nenadic, Nenad G.

Gear Fault Detection Effectiveness as Applied to Tooth Surface Pitting Fatigue Damage

A study was performed to evaluate fault detection effectiveness as applied to gear-tooth-pitting-fatigue damage. Vibration and oil-debris monitoring (ODM) data were gathered from 24 sets of spur pinion and face gears run during a previous endurance evaluation study. Three common condition indicators (RMS, FM4, and NA4 [Ed. 's note: See Appendix A-Definitions D were deduced from the time-averaged vibration data and used with the ODM to evaluate their performance for gear fault detection. The NA4 parameter showed to be a very good condition indicator for the detection of gear tooth surface pitting failures. The FM4 and RMS parameters perfomu:d average to below average in detection of gear tooth surface pitting failures. The ODM sensor was successful in detecting a significant 8lDOunt of debris from all the gear tooth pitting fatigue failures. Excluding outliers, the average cumulative mass at the end of a test was 40 mg.

Lewicki, David G.

Offset Compound Gear Drive

The Offset Compound Gear Drive is an in-line, discrete, two-speed device utilizing a special offset compound gear that has both an internal tooth configuration on the input end and external tooth configuration on the output end, thus allowing it to mesh in series, simultaneously, with both a smaller external tooth input gear and a larger internal tooth output gear. This unique geometry and offset axis permits the compound gear to mesh with the smaller diameter input gear and the larger diameter output gear, both of which are on the same central, or primary, centerline. This configuration results in a compact in-line reduction gear set consisting of fewer gears and bearings than a conventional planetary gear train. Switching between the two output ratios is accomplished through a main control clutch and sprag. Power flow to the above is transmitted through concentric power paths. Low-speed operation is accomplished in two meshes. For the purpose of illustrating the low-speed output operation, the following example pitch diameters are given. A 5.0 pitch diameter (PD) input gear to 7.50 PD (internal tooth) intermediate gear (0.667 reduction mesh), and a 7.50 PD (external tooth) intermediate gear to a 10.00 PD output gear (0.750 reduction mesh). Note that it is not required that the intermediate gears on the offset axis be of the same diameter. For this example, the resultant low-speed ratio is 2:1 (output speed = 0.500; product of stage one 0.667 reduction and stage two 0.750 stage reduction). The design is not restricted to the example pitch diameters, or output ratio. From the output gear, power is transmitted through a hollow drive shaft, which, in turn, drives a sprag during which time the main clutch is disengaged.

Stevens, Mark A.

Two-Speed Gearbox Dynamic Simulation Predictions and Test Validation

Dynamic simulations and experimental validation tests were performed on a two-stage, two-speed gearbox as part of the drive system research activities of the NASA Fundamental Aeronautics Subsonics Rotary Wing Project. The gearbox was driven by two electromagnetic motors and had two electromagnetic, multi-disk clutches to control output speed. A dynamic model of the system was created which included a direct current electric motor with proportional-integral-derivative (PID) speed control, a two-speed gearbox with dual electromagnetically actuated clutches, and an eddy current dynamometer. A six degree-of-freedom model of the gearbox accounted for the system torsional dynamics and included gear, clutch, shaft, and load inertias as well as shaft flexibilities and a dry clutch stick-slip friction model. Experimental validation tests were performed on the gearbox in the NASA Glenn gear noise test facility. Gearbox output speed and torque as well as drive motor speed and current were compared to those from the analytical predictions. The experiments correlate very well with the predictions, thus validating the dynamic simulation methodologies.

Lewicki, David G.

Gear Fault Detection Effectiveness as Applied to Tooth Surface Pitting Fatigue Damage

A study was performed to evaluate fault detection effectiveness as applied to gear tooth pitting fatigue damage. Vibration and oil-debris monitoring (ODM) data were gathered from 24 sets of spur pinion and face gears run during a previous endurance evaluation study. Three common condition indicators (RMS, FM4, and NA4) were deduced from the time-averaged vibration data and used with the ODM to evaluate their performance for gear fault detection. The NA4 parameter showed to be a very good condition indicator for the detection of gear tooth surface pitting failures. The FM4 and RMS parameters performed average to below average in detection of gear tooth surface pitting failures. The ODM sensor was successful in detecting a significant amount of debris from all the gear tooth pitting fatigue failures. Excluding outliers, the average cumulative mass at the end of a test was 40 mg.

Lewicki, David G.

Variable/Multispeed Rotorcraft Drive System Concepts

Several recent studies for advanced rotorcraft have identified the need for variable, or multispeed-capable rotors. A speed change of up to 50 percent has been proposed for future rotorcraft to improve vehicle performance. Varying rotor speed during flight not only requires a rotor capable of performing effectively over the extended operation speed and load range, but also requires an advanced propulsion system to provide the required speed changes. A study has been completed, which investigated possible drive system arrangements to accommodate up to the 50 percent speed change. These concepts are presented. The most promising configurations are identified and will be developed for future validation testing.

Stevens, Mark A.

Concepts for Variable/Multi-Speed Rotorcraft Drive System

In several recent studies and on-going developments for advanced rotorcraft, the need for variable or multi-speed capable rotors has been raised. A speed change of up to 50 percent has been proposed for future rotorcraft to improve overall vehicle performance. Accomplishing rotor speed changes during operation requires both a rotor that can perform effectively over the operation speed/load range, and a propulsion system that can enable these speed changes. A study has been completed to investigate possible drive system arrangements that can accommodate up to the 50 percent speed change. Several concepts will be presented and evaluated. The most promising configurations will be identified and developed for future testing in a sub-scaled test facility to validate operational capability.

Stevens, Mark A.