Engineering topics

Lewicki, David G.

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

At least 55 records · Page 3

NASA NTRS2001

Gear Crack Propagation Path Studies: Guidelines for Ultra-Safe Design

Design guidelines have been established to prevent catastrophic rim fracture failure modes when considering gear tooth bending fatigue. Analysis was performed using the finite element method with principles of linear elastic fracture mechanics. Crack propagation paths were predicted for a variety of gear tooth and rim configurations. The effects of rim and web thicknesses, initial crack locations, and gear tooth geometry factors such as diametral pitch, number of teeth, pitch radius, and tooth pressure angle were considered. Design maps of tooth/rim fracture modes including effects of gear geometry, applied load, crack size, and material properties were developed. The occurrence of rim fractures significantly increased as the backup ratio (rim thickness divided by tooth height) decreased. The occurrence of rim fractures also increased as the initial crack location was moved down the root of the tooth. Increased rim and web compliance increased the occurrence of rim fractures. For gears with constant pitch radii, coarser-pitch teeth increased the occurrence of tooth fractures over rim fractures. Also, 25 deg pressure angle teeth had an increased occurrence of tooth fractures over rim fractures when compared to 20 deg pressure angle teeth. For gears with constant number of teeth or gears with constant diametral pitch, varying size had little or no effect on crack propagation paths.

Lewicki, David G.↗

NASA NTRS2001

Consideration of Moving Tooth Load in Gear Crack Propagation Predictions

Robust gear designs consider not only crack initiation, but crack propagation trajectories for a fail-safe design. In actual gear operation, the magnitude as well as the position of the force changes as the gear rotates through the mesh. A study to determine the effect of moving gear tooth load on crack propagation predictions was performed. Two-dimensional analysis of an involute spur gear and three-dimensional analysis of a spiral-bevel pinion gear using the finite element method and boundary element method were studied and compared to experiments. A modified theory for predicting gear crack propagation paths based on the criteria of Erdogan and Sih was investigated. Crack simulation based on calculated stress intensity factors and mixed mode crack angle prediction techniques using a simple static analysis in which the tooth load was located at the highest point of single tooth contact was validated. For three-dimensional analysis, however, the analysis was valid only as long as the crack did not approach the contact region on the tooth.

Lewicki, David G.↗

NASA NTRS2001

The Application of Time-Frequency Methods to HUMS

This paper reports the study of four time-frequency transforms applied to vibration signals and presents a new metric for comparing them for fault detection. The four methods to be described and compared are the Short Time Frequency Transform (STFT), the Choi-Williams Distribution (WV-CW), the Continuous Wavelet Transform (CWT) and the Discrete Wavelet Transform (DWT). Vibration data of bevel gear tooth fatigue cracks, under a variety of operating load levels, are analyzed using these methods. The new metric for automatic fault detection is developed and can be produced from any systematic numerical representation of the vibration signals. This new metric reveals indications of gear damage with all of the methods on this data set. Analysis with the CWT detects mechanical problems with the test rig not found with the other transforms. The WV-CW and CWT use considerably more resources than the STFT and the DWT. More testing of the new metric is needed to determine its value for automatic fault detection and to develop methods of setting the threshold for the metric.

Pryor, Anna H.↗

NASA NTRS2000

Experimental Analysis of Mast Lifting and Bending Forces on Vibration Patterns Before and After Pinion Reinstallation in an OH-58 Transmission Test Rig

As part of a collaborative research program between NASA Ames Research Center (ARC), NASA Glenn Research Center (GRC), and the US Army Laboratory, a series of experiments is being performed in GRC's 500 HP OH-58 Transmission Test Rig facility and ARC's AH-I Cobra and OH-58c helicopters. The findings reported in this paper were drawn from Phase-I of a two-phase test-rig experiment, and are focused on the vibration response of an undamaged pinion gear operating in the transmission test rig. To simulate actual flight conditions, the transmission system was run at three torque levels, as well as two mast lifting and two mast bending levels. The test rig was also subjected to disassembly and reassembly of the main pinion housing to simulate the effect of maintenance operations. An analysis of variance based on the total power of the spectral distribution indicates the relative effect of each experimental factor, including Wong interactions with torque. Reinstallation of the main pinion assembly is shown to introduce changes in the vibration signature, suggesting the possibility of a strong effect of maintenance on HUMS design and use. Based on these results, further research will be conducted to compare these vibration responses with actual OH58c helicopter transmission vibration patterns.

Huff, Edward M.↗

NASA NTRS1999

Evaluation of Carburized and Ground Face Gears

Experimental durability tests were performed on carburized and ground AIS19310 steel face gears. The tests were in support of a Defense Advanced Research Projects Agency (DARPA) Technology Reinvestment Program (TRP) to enhance face-gear technology. The tests were conducted in the NASA Glenn spiral-bevel-gear/face-gear test facility. Tests were run at 2300 rpm face gear speed and at loads of 64, 76, 88, 100, and 112-percent of the design torque of 377 N-m (3340 in-lb). The carburized and ground face gears demonstrated the required durability when run for ten-million cycles at each of the applied loads. Proper installation was critical for the successful operation of the spur pinions and face gears. A large amount of backlash produced tooth contact patterns that approached the inner-diameter edge of the face-gear tooth. Low backlash produced tooth contact patterns that approached the outer-diameter edge of the face-gear tooth. Measured backlashes in the range of 0.178 to 0.254 mm (0.007 to 0.010 in) produced acceptable tooth contact patterns.

Lewicki, David G.↗

NASA NTRS1999

Three-Dimensional Gear Crack Propagation Studied

Gears used in current helicopters and turboprops are designed for light weight, high margins of safety, and high reliability. However, unexpected gear failures may occur even with adequate tooth design. To design an extremely safe system, the designer must ask and address the question, "What happens when a failure occurs?" With gear-tooth bending fatigue, tooth or rim fractures may occur. A crack that propagates through a rim will be catastrophic, leading to disengagement of the rotor or propeller, loss of an aircraft, and possible fatalities. This failure mode should be avoided. A crack that propagates through a tooth may or may not be catastrophic, depending on the design and operating conditions. Also, early warning of this failure mode may be possible because of advances in modern diagnostic systems. One concept proposed to address bending fatigue fracture from a safety aspect is a splittooth gear design. The prime objective of this design would be to control crack propagation in a desired direction such that at least half of the tooth would remain operational should a bending failure occur. A study at the NASA Lewis Research Center analytically validated the crack-propagation failsafe characteristics of a split-tooth gear. It used a specially developed three-dimensional crack analysis program that was based on boundary element modeling and principles of linear elastic fracture mechanics. Crack shapes as well as the crack-propagation life were predicted on the basis of the calculated stress intensity factors, mixed-mode crack-propagation trajectory theories, and fatigue crack-growth theories. The preceding figures show the effect of the location of initial cracks on crack propagation. Initial cracks in the fillet of the teeth produced stress intensity factors of greater magnitude (and thus, greater crack growth rates) than those in the root or groove areas of the teeth. Crack growth was simulated in a case study to evaluate crack-propagation paths. Tooth fracture was predicted from the crackgrowth simulation for an initial crack in the tooth fillet region. This was the desired failure mode for an ultrasafe design. Lastly, tooth loads on the uncracked mesh of the split-tooth design were up to five times greater than those on the cracked mesh if equal deflections of the cracked and uncracked teeth were considered. This effect needs to be considered in the design of a split-tooth configuration. This work was done in-house at Lewis in support of the National Rotorcraft Technology Center project, Ultra-Safe Gear Design, with the Boeing Defense and Space Group. The crack-propagation package was developed by the Cornell Fracture Group at Cornell University. The reported results, which are the initial findings of Lewis gear-crackpropagation research for the Rotorcraft Base Program, will be further investigated to develop generalized gear design guidelines.

Lewicki, David G.↗

NASA NTRS1998

Three-Dimensional Gear Crack Propagation Studies

Three-dimensional crack growth simulation was performed on a split-tooth gear design using boundary element modeling and linear elastic fracture mechanics. Initial cracks in the fillet of the teeth produced stress intensity factors of greater magnitude (and thus, greater crack growth rates) than those in the root or groove areas of the teeth. Crack growth simulation was performed on a case study to evaluate crack propagation paths. Tooth fracture was predicted from the crack growth simulation for an initial crack in the tooth fillet region. Tooth loads on the uncracked mesh of the split-tooth design were up to five times greater than those on the cracked mesh if equal deflections of the cracked and uncracked teeth were considered. Predicted crack shapes as well as crack propagation life are presented based on calculated stress intensity factors, mixed-mode crack propagation trajectory theories, and fatigue crack growth theories.

Lewicki, David G.↗

NASA NTRS1996

Improving the Performance of the Structure-Based Connectionist Network for Diagnosis of Helicopter Gearboxes

A diagnostic method is introduced for helicopter gearboxes that uses knowledge of the gear-box structure and characteristics of the 'features' of vibration to define the influences of faults on features. The 'structural influences' in this method are defined based on the root mean square value of vibration obtained from a simplified lumped-mass model of the gearbox. The structural influences are then converted to fuzzy variables, to account for the approximate nature of the lumped-mass model, and used as the weights of a connectionist network. Diagnosis in this Structure-Based Connectionist Network (SBCN) is performed by propagating the abnormal vibration features through the weights of SBCN to obtain fault possibility values for each component in the gearbox. Upon occurrence of misdiagnoses, the SBCN also has the ability to improve its diagnostic performance. For this, a supervised training method is presented which adapts the weights of SBCN to minimize the number of misdiagnoses. For experimental evaluation of the SBCN, vibration data from a OH-58A helicopter gearbox collected at NASA Lewis Research Center is used. Diagnostic results indicate that the SBCN is able to diagnose about 80% of the faults without training, and is able to improve its performance to nearly 100% after training.

Jammu, Vinay B.↗

NASA NTRS1996

Detecting Faults In Helicopter Gearboxes By The MVIM Method

Multivalued influence-matrix (MVIM) method potential utility as theoretical basis of proposed automated monitoring systems detecting faults in helicopter gearboxes. Applied to recognize patterns in vibration measurements. Fault-recognition system required to operate continuously while helicopter airborne, analyzing measurements of vibrations for signs of trouble to provide real-time warning of any dangerous or potentially dangerous fault like cracked case or fractured gear tooth. System also required not to give false alarms to prevent unnecessary emergency landings.

Chin, Hsinyung↗

NASA NTRS1996

Model-based sensor location selection for helicopter gearbox monitoring

A new methodology is introduced to quantify the significance of accelerometer locations for fault diagnosis of helicopter gearboxes. The basis for this methodology is an influence model which represents the effect of various component faults on accelerometer readings. Based on this model, a set of selection indices are defined to characterize the diagnosability of each component, the coverage of each accelerometer, and the relative redundancy between the accelerometers. The effectiveness of these indices is evaluated experimentally by measurement-fault data obtained from an OH-58A main rotor gearbox. These data are used to obtain a ranking of individual accelerometers according to their significance in diagnosis. Comparison between the experimentally obtained rankings and those obtained from the selection indices indicates that the proposed methodology offers a systematic means for accelerometer location selection.

Jammu, Vinay B.↗

NASA NTRS1996

Gear crack propagation investigations

Analytical and experimental studies were performed to investigate the effect of gear rim thickness on crack propagation life. The FRANC (FRacture ANalysis Code) computer program was used to simulate crack propagation. The FRANC program used principles of linear elastic fracture mechanics, finite element modeling, and a unique re-meshing scheme to determine crack tip stress distributions, estimate stress intensity factors, and model crack propagation. Various fatigue crack growth models were used to estimate crack propagation life based on the calculated stress intensity factors. Experimental tests were performed in a gear fatigue rig to validate predicted crack propagation results. Test gears were installed with special crack propagation gages in the tooth fillet region to measure bending fatigue crack growth. Good correlation between predicted and measured crack growth was achieved when the fatigue crack closure concept was introduced into the analysis. As the gear rim thickness decreased, the compressive cyclic stress in the gear tooth fillet region increased. This retarded crack growth and increased the number of crack propagation cycles to failure.

Lewicki, David G.↗

NASA NTRS1996

Detecting Gear Tooth Fatigue Cracks in Advance of Complete Fracture

Results of using vibration-based methods to detect gear tooth fatigue cracks are presented. An experimental test rig was used to fail a number of spur gear specimens through bending fatigue. The gear tooth fatigue crack in each test was initiated through a small notch in the fillet area of a tooth on the gear. The primary purpose of these tests was to verify analytical predictions of fatigue crack propagation direction and rate as a function of gear rim thickness. The vibration signal from a total of three tests was monitored and recorded for gear fault detection research. The damage consisted of complete rim fracture on the two thin rim gears and single tooth fracture on the standard full rim test gear. Vibration-based fault detection methods were applied to the vibration signal both on-line and after the tests were completed. The objectives of this effort were to identify methods capable of detecting the fatigue crack and to determine how far in advance of total failure positive detection was given. Results show that the fault detection methods failed to respond to the fatigue crack prior to complete rim fracture in the thin rim gear tests. In the standard full rim gear test all of the methods responded to the fatigue crack in advance of tooth fracture; however, only three of the methods responded to the fatigue crack in the early stages of crack propagation.

Zakrajsek, James J.↗

NASA NTRS1996

Unsupervised Pattern Classifier for Abnormality-Scaling of Vibration Features for Helicopter Gearbox Fault Diagnosis

A new unsupervised pattern classifier is introduced for on-line detection of abnormality in features of vibration that are used for fault diagnosis of helicopter gearboxes. This classifier compares vibration features with their respective normal values and assigns them a value in (0, 1) to reflect their degree of abnormality. Therefore, the salient feature of this classifier is that it does not require feature values associated with faulty cases to identify abnormality. In order to cope with noise and changes in the operating conditions, an adaptation algorithm is incorporated that continually updates the normal values of the features. The proposed classifier is tested using experimental vibration features obtained from an OH-58A main rotor gearbox. The overall performance of this classifier is then evaluated by integrating the abnormality-scaled features for detection of faults. The fault detection results indicate that the performance of this classifier is comparable to the leading unsupervised neural networks: Kohonen's Feature Mapping and Adaptive Resonance Theory (AR72). This is significant considering that the independence of this classifier from fault-related features makes it uniquely suited to abnormality-scaling of vibration features for fault diagnosis.

Jammu, Vinay B.↗

NASA NTRS1995

Diagnosis of helicopter gearboxes using structure-based networks

A connectionist network is introduced for fault diagnosis of helicopter gearboxes that incorporates knowledge of the gearbox structure and characteristics of the vibration features as its fuzzy weights. Diagnosis is performed by propagating the abnormal features of vibration measurements through this Structure-Based Connectionist Network (SBCN), the outputs of which represent the fault possibility values for individual components of the gearbox. The performance of this network is evaluated by applying it to experimental vibration data from an OH-58A helicopter gearbox. The diagnostic results indicate that the network performance is comparable to those obtained from supervised pattern classification.

Jammu, Vinay B.↗

NASA NTRS1995

Detecting gear tooth fracture in a high contact ratio face gear mesh

This paper summarized the results of a study in which three different vibration diagnostic methods were used to detect gear tooth fracture in a high contact ratio face gear mesh. The NASA spiral bevel gear fatigue test rig was used to produce unseeded fault, natural failures of four face gear specimens. During the fatigue tests, which were run to determine load capacity and primary failure mechanisms for face gears, vibration signals were monitored and recorded for gear diagnostic purposes. Gear tooth bending fatigue and surface pitting were the primary failure modes found in the tests. The damage ranged from partial tooth fracture on a single tooth in one test to heavy wear, severe pitting, and complete tooth fracture of several teeth on another test. Three gear fault detection techniques, FM4, NA4*, and NB4, were applied to the experimental data. These methods use the signal average in both the time and frequency domain. Method NA4* was able to conclusively detect the gear tooth fractures in three out of the four fatigue tests, along with gear tooth surface pitting and heavy wear. For multiple tooth fractures, all of the methods gave a clear indication of the damage. It was also found that due to the high contact ratio of the face gear mesh, single tooth fractures did not significantly affect the vibration signal, making this type of failure difficult to detect.

Zakrajsek, James J.↗

NASA NTRS1994

Low-Noise Spiral Bevel Gears

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.

Lewicki, David G.↗

NASA NTRS1994

Improvements in Spiral-Bevel Gears to Reduce Noise and Increase Strength

Advanced-design spiral-bevel gears were tested in an OH-58D helicopter transmission using the NASA 500 hp Helicopter Transmission Test Stand. Four different gear designs were tested. The four designs tested were the current design of the OH-58D transmission, a higher-strength design the same as the current but with an increased fillet radius to reduce gear tooth bending stress, and two versions of a lower-noise design the same as the high-strength but with modified tooth geometry to reduce transmission error and noise. Noise, vibration, and tooth strain tests were performed and significant gear stress and noise reductions were achieved.

Lewicki, David G.↗

NASA NTRS1993

Low-noise, high-strength, spiral-bevel gears for helicopter transmissions

Improvements in spiral-bevel gear design were investigated to support the Army/NASA Advanced Rotorcraft Transmission program. Program objectives were to reduce weight by 25 percent, reduce noise by 10 dB, and increase life to 5000 hr mean-time-between-removal. To help meet these goals, advanced-design spiral-bevel gears were tested in an OH-58D helicopter transmission using the NASA 500-hp Helicopter Transmission Test Stand. Three different gear designs tested included: (1) the current design of the OH-58D transmission except gear material X-53 instead of AISI 9310; (2) a higher-strength design the same as the current but with a full fillet radius to reduce gear tooth bending stress (and thus, weight); and (3) a lower-noise design the same as the high-strength but with modified tooth geometry to reduce transmission error and noise. Noise, vibration, and tooth strain tests were performed and significant gear stress and noise reductions were achieved.

Lewicki, David G.↗