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All sourcesNASA NTRSDOE OSTI
NASA NTRS1997

Remote Sensing of Surficial Process Responses to Extreme Meteorological Events

Changes in the frequency and magnitude of extreme meteorological events are associated with changing environmental means. Such events are important in human affairs, and can also be investigated by orbital remote sensing. During the course of this project, we applied ERS-1, ERS-2, Radarsat, and an airborne sensor (AIRSAR-TOPSAR) to measure flood extents, flood water surface profiles, and flood depths. We established a World Wide Web site (the Dartmouth Flood Observatory) for publishing remote sensing-based maps of contemporary floods worldwide; this is also an online "active archive" that presently constitutes the only global compilation of extreme flood events. We prepared an article for EOS concerning SAR imaging of the Mississippi Valley flood; an article for the International Journal of Remote Sensing on measurement of a river flood wave using ERS-2, began work on an article (since completed and published) on the Flood Observatory for a Geoscience Information Society Proceedings volume, and presented lectures at several Geol. Soc. of America Natl. Meetings, an Assoc. of Amer. Geographers Natl. Meeting, and a Binghamton Geomorphology Symposium (all on SAR remote sensing of the Mississippi Valley flood). We expanded in-house modeling capabilities by installing the latest version of the Army Corps of Engineers RMA two-dimensional hydraulics software and BYU Engineering Graphics Lab's Surface Water Modeling System (finite elements based pre- and post-processors for RMA work) and also added watershed modeling software. We are presently comparing the results of the 2-d flow models with SAR image data. The grant also supported several important upgrades of pc-based remote sensing infrastructure at Dartmouth. During work on this grant, we collaborated with several workers at the U.S. Army Corps of Engineers, Remote Sensing/GIS laboratory (for flood inundation mapping and modeling; particularly of the Illinois River using the AIRSAR/TOPSAR/ERS-2 combined data), with Dr. Karen Prestegaard at the University of Maryland (geomorphological responses to the extreme 1993 flood along the Raccoon drainage in central Iowa), and with Mr Tim Scrom of the Albany National Weather Service River Forecast Center (initial planning for the use of Radarsat and ERS-2 for flood warning). The work thus initiated with this proposal is continuing.

Brakenridge, G. Robert↗
NASA NTRS1998

Flight Testing and Real-Time System Identification Analysis of a UH-60A Black Hawk Helicopter with an Instrumented External Sling Load

Helicopter external air transportation plays an important role in today's world. For both military and civilian helicopters, external sling load operations offer an efficient and expedient method of handling heavy, oversized cargo. With the ability to reach areas otherwise inaccessible by ground transportation, helicopter external load operations are conducted in industries such as logging, construction, and fire fighting, as well as in support of military tactical transport missions. Historically, helicopter and load combinations have been qualified through flight testing, requiring considerable time and cost. With advancements in simulation and flight test techniques there is potential to substantially reduce costs and increase the safety of helicopter sling load certification. Validated simulation tools make possible accurate prediction of operational flight characteristics before initial flight tests. Real time analysis of test data improves the safety and efficiency of the testing programs. To advance these concepts, the U.S. Army and NASA, in cooperation with the Israeli Air Force and Technion, under a Memorandum of Agreement, seek to develop and validate a numerical model of the UH-60 with sling load and demonstrate a method of near real time flight test analysis. This thesis presents results from flight tests of a U.S. Army Black Hawk helicopter with various external loads. Tests were conducted as the U.S. first phase of this MOA task. The primary load was a container express box (CONEX) which contained a compact instrumentation package. The flights covered the airspeed range from hover to 70 knots. Primary maneuvers were pitch and roll frequency sweeps, steps, and doublets. Results of the test determined the effect of the suspended load on both the aircraft's handling qualities and its control system's stability margins. Included were calculations of the stability characteristics of the load's pendular motion. Utilizing CIFER(R) software, a method for near-real time system identification was also demonstrated during the flight test program.

McCoy, Allen H.↗
NASA NTRS1998

Virtual Environment Computer Simulations to Support Human Factors Engineering and Operations Analysis for the RLV Program

The Army-NASA Virtual Innovations Laboratory (ANVIL) was recently created to provide virtual reality tools for performing Human Engineering and operations analysis for both NASA and the Army. The author's summer research project consisted of developing and refining these tools for NASA's Reusable Launch Vehicle (RLV) program. Several general simulations were developed for use by the ANVIL for the evaluation of the X34 Engine Changeout procedure. These simulations were developed with the software tool dVISE 4.0.0 produced by Division Inc. All software was run on an SGI Indigo2 High Impact. This paper describes the simulations, various problems encountered with the simulations, other summer activities, and possible work for the future. We first begin with a brief description of virtual reality systems.

Lunsford, Myrtis Leigh↗
NASA NTRS2000

Future Directions in Rotorcraft Technology at Ames Research Center

Members of the NASA and Army rotorcraft research community at Ames Research Center have developed a vision for 'Vertical Flight 2025'. This paper describes the development of that vision and the steps being taken to implement it. In an effort to realize the vision, consistent with both NASA and Army Aviation strategic plans, two specific technology development projects have been identified: (1) one focused on a personal transportation system capable of vertical flight (the 'Roto-Mobile') and (2) the other on small autonomous rotorcraft (which is inclusive of vehicles which range in grams of gross weight for 'MicroRotorcraft' to thousands of kilograms for rotorcraft uninhabited aerial vehicles). The paper provides a status report on these projects as well as a summary of other revolutionary research thrusts being planned and executed at Ames Research Center.

Aiken, Edwin W.↗
NASA NTRS2001

SHARP-B2: Flight Test Objectives, Project Implementation and Initial Results

On September 28, 2000 the SHARP-B2 flight experiment was launched from Vandenberg Air Force Base, California. SHARP-B2 is the 2nd Ballistic flight test in the SHARP (Slender Hypervelocity Aerothermodynamic Research Probes) program which develops and tests new thermal protection materials and sharp body concepts. The flight tested Ultra-High Temperature Ceramics (UHTCs), which may radically change the design and performance of future aerospace vehicles. The new designs may overturn an age-old tenet of aerodynamics: that blunt-body aerospace vehicles, but not those with sharp leading edges, can survive the searing temperatures created as the vehicles tear through the atmosphere. Sharp leading edges offer numerous advantages over the blunt-body design currently in use. They could allow a space shuttle or crew return vehicle to maneuver in space more like an airplane and potentially allow astronauts to return to Earth from anywhere on orbit. They may allow improved astronaut safety by decreasing the risk of aborting into the ocean. They may reduce the electromagnetic interference that causes the communications blackouts that plague reentering blunt-body space vehicles. Reducing the amount of drag could lead to a reduction in propulsion requirements. Planetary probes could make use of sharp-body technology for aerobraking and to maximize their maneuvering capability. SHARP-B2 was a joint effort among NASA Ames, Sandia National Laboratories, the U.S. Air Force and the U.S. Army. It was funded by the Pathfinder Program at NASA's Marshall Space Flight Center. The SHARP-B2 payload was carried aboard a U.S. Air Force Minuteman III missile carrying a modified Mk 12A reentry vehicle (RV), which blasted off from Vandenberg Air Force Base near Lompoc, CA, at 3:01 a.m. PDT on Sept. 28. The RV was equipped with four 5. 1 inch-long strakes, or sharp leading edges. Each strake contained three UHTCs: ZrB2/SiC/C; ZrB2/SiC; and HfB2/SiC. Once it reached an altitude of about 400 nautical miles, the RV was released, returning through Earth's atmosphere at speeds exceeding Mach 22. One pair of strakes was designed to retract just before reaching temperatures high enough to cause the material to begin ablating. The other pair was designed to retract shortly after ablation began, at an expected temperature of nearly 5,100 degrees Fahrenheit. Sensors in the strakes measured how closely performance matched pre-flight calculations, and data was successfully collected throughout the 23-minute flight. A parachute was deployed (but not fully inflated) and the RV splashed down in a lagoon at the Kwajalein missile range in the Pacific Ocean. Within 3 hours radar track analysis showed ocean entry to be precisely at the latitude/longitude coordinates estimated during pre-flight simulation. An hour later a ship was deployed by the Army to recover the reentry vehicle, which was recovered in 165 feet of water, just 500 feet from its planned splash-down point. This is the first RV recovery in over a decade.

Salute, Joan↗
NASA NTRS2001

National Environmental Change Information System Case Study

The Global Hydrology and Climate Center and NASA's Marshall Space Flight Center conducted a fact-finding case study for the Data Management Working Group (DMWG), now referred to as the Data and Information Working Group (DIWG), of the U.S. Global Change Research Program (USGCRP) to determine the feasibility of an interagency National Environmental Change Information System (NECIS). In order to better understand the data and information needs of policy and decision makers at the national, state, and local level, the DIWG asked the case study team to choose a regional water resources issue in the southeastern United States that had an impact on a diverse group of stakeholders. The southeastern United States was also of interest because the region experiences interannual climatic variations and impacts due to El Nino and La Nina. Jointly, with input from the DIWG, a focus on future water resources planning in the Apalachicola-Chattahoochee-Flint (ACF) River basins of Alabama, Georgia, and Florida was selected. A tristate compact and water allocation formula is currently being negotiated between the states and U.S. Army Corps of Engineers (COE) that will affect the availability of water among competing uses within the ACF River basin. All major reservoirs on the ACF are federally owned and operated by the U.S. Army COE. A similar two-state negotiation is ongoing that addresses the water allocations in the adjacent Alabama-Coosa-Tallapoosa (ACT) River basin, which extends from northwest Georgia to Mobile Bay. The ACF and ACT basins are the subject of a comprehensive river basin study involving many stakeholders. The key objectives of this case study were to identify specific data and information needs of key stakeholders in the ACF region, determine what capabilities are needed to provide the most practical response to these user requests, and to identify any limitations in the use of federal data and information. The NECIS case study followed the terms of reference developed by the interagency DIWG. The case study "lessons learned" and "key findings" offer guidelines and considerations to the DMWG for the development and implementation of a NECIS that would support the data and information needs of policy and decision makers at the national, state, and local level.

Goodman, S. J.↗
NASA NTRS1995

Simulator Investigation of Pilot Aids for Helicopter Terminal Area Operations with One Engine Inoperative

Two recent piloted simulation experiments have investigated advanced display concepts applied to civil transport helicopter terminal area operations. Civil Category A helicopter operations apply to multi-engine helicopters wherein a safe recovery (land or fly out) is required in the event of a single engine failure. The investigation used the NASA Ames Research Center Vertical Motion Simulator, which has a full six degrees of freedom, to simulate the flight task as closely as possible. The goal of these experiments was to use advanced cockpit displays to improve flight safety and enhance the mission performance of Category A terminal area operations in confined areas. The first experiment investigated the use of military display formats to assist civil rotorcraft in performing a Category A takeoff in confined terminal areas. Specifically, it addressed how well a difficult hovering backup path could be followed using conventional instruments in comparison to panel mounted integrated displays. The hovering backup takeoff, which enables pilots to land back to the confined area pad in the event of an engine failure, was chosen since it is a difficult task to perform. Seven NASA and Army test pilots participated in the experiment. Evaluations, based on task performance and pilot workload, showed that an integrated display enabled the pilot to consistently achieve adequate or desired performance with reasonable pilot workload. Use of conventional instruments, however, frequently resulted in unacceptable performance (poor flight path tracking), higher pilot workload, and poor situational awareness. Although OEI landbacks were considered a visual task, the improved performance on the backup portion, in conjunction with increased situational awareness resulting from use of integrated displays, enabled the pilots to handle an engine failure and land back safely. In contrast, use of conventional instruments frequently led to excessive rates of sink at touchdown. A second simulation (in progress - July - August) is being conducted to investigate the use of advanced displays to perform vertical and short takeoffs and landings. One Engine Inoperative trajectories, which were optimized based on safety of flight restrictions, are utilized. Based on comments from the first experiment and further analytic development, appropriate fly out and approach guidance was added. Displays include conventional instruments with raw data, and the following integrated displays: multi-view and side-view hover displays based on the Apache Pilot Night Vision System, and variations of the pathway-in-the-sky displays with a flight-path-vector, a leader and flight director modifications. Panel mounted and head-up displays are being evaluated. Engine modifications have been incorporated to simulate 30 second and 2 minute contingency power ratings. Evaluations are based on task performance and pilot workload. NASA, Army, FAA, and industry test pilots participated. Details concerning the design, conduct, and the results of the experiment will be reported in the proposed paper.

Iseler, Laura↗
NASA NTRS1993

Small Business Innovations

Under an Army Small Business Innovation Research (SBIR) grant, Symbiotics, Inc. developed a software system that permits users to upgrade products from standalone applications so they can communicate in a distributed computing environment. Under a subsequent NASA SBIR grant, Symbiotics added additional tools to the SOCIAL product to enable NASA to coordinate conventional systems for planning Shuttle launch support operations. Using SOCIAL, data may be shared among applications in a computer network even when the applications are written in different programming languages. The product was introduced to the commercial market in 1993 and is used to monitor and control equipment for operation support and to integrate financial networks. The SBIR program was established to increase small business participation in federal R&D activities and to transfer government research to industry. InQuisiX is a reuse library providing high performance classification, cataloging, searching, browsing, retrieval and synthesis capabilities. These form the foundation for software reuse, producing higher quality software at lower cost and in less time. Software Productivity Solutions, Inc. developed the technology under Small Business Innovation Research (SBIR) projects funded by NASA and the Army and is marketing InQuisiX in conjunction with Science Applications International Corporation (SAIC). The SBIR program was established to increase small business participation in federal R&D activities and to transfer government research to industry.

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NASA NTRS2002

Airworthiness Qualification Criteria for Rotorcraft with External Sling Loads

This report presents the results of a study to develop airworthiness requirements for rotorcraft with external sling loads. The report starts with a review of the various phenomena that limit external sling load operations. Specifically discussed are the rotorcraft-load aeroservoelastic stability, load-on handling qualities, effects of automatic flight control system failure, load suspension system failure, and load stability at speed. Based on past experience and treatment of these phenomena, criteria are proposed to form a package for airworthiness qualification. The desired end objective is a set of operational flight envelopes for the rotorcraft with intended loads that can be provided to the user to guide operations in the field. The specific criteria proposed are parts of ADS-33E-PRF; MIL-F-9490D, and MIL-STD-913A all applied in the context of external sling loads. The study was performed for the Directorate of Engineering, U.S. Army Aviation and Missile Command (AMCOM), as part of the contract monitored by the Aerothermodynamics Directorate, U.S. Army AMCOM.

Key, David L.↗
NASA NTRS2000

Initial Flight Evaluation of the Army/NASA RASCAL Variable Stability Helicopter

NASA Ames Research Center and the U.S. Army Aeroflightdynamics Directorate (AFDD) [will] have performed initial flight evaluations of the Research Flight Control System (RFCS) that has been integrated into the Army/NASA Rotorcraft Aircrew Systems Concepts Airborne Laboratory (RASCAL) variable stability helicopter. The RASCAL, a highly modified JUH-60A Black Hawk helicopter, is a variable-stability, in-flight simulator that is designed to support flight research programs that leverage on the flight control and handling qualities design tools developed by the Army and NASA. These tools are used in the flight control design life cycle from initial concept definition, through simulation, and ultimately into flight on-board the RASCAL helicopter. The RASCAL will be used to validate methodologies for reducing design cycle costs for new or modified aircraft, and it will serve as a base for the investigation of new rotorcraft technology.

Moralez, Ernesto, III↗
NASA NTRS2002

Evaluation of Impinging Stream Vortex Chamber Concepts for Liquid Rocket Engine Applications

To pursue technology developments for future launch vehicles, NASA/Marshall Space Flight Center (MSFC) is examining vortex chamber concepts for liquid rocket engine applications. Past studies indicated that the vortex chamber schemes potentially have a number of advantages over conventional chamber methods. Due to the nature of the vortex flow, relatively cooler propellant streams tend to flow along the chamber wall. Hence, the thruster chamber can be operated without the need of any cooling techniques. This vortex flow also creates strong turbulence, which promotes the propellant mixing process. Consequently, the subject chamber concepts not only offer system simplicity, but also enhance the combustion performance. Test results have shown that chamber performance is markedly high even at a low chamber length-to-diameter ratio (LD). This incentive can be translated to a convenience in the thrust chamber packaging. Variations of the vortex chamber concepts have been introduced in the past few decades. These investigations include an ongoing work at Orbital Technologies Corporation (ORBITEC). By injecting the oxidizer tangentially at the chamber convergence and fuel axially at the chamber head end, Knuth et al. were able to keep the wall relatively cold. A recent investigation of the low L/D vortex chamber concept for gel propellants was conducted by Michaels. He used both triplet (two oxidizer orifices and one fuel orifice) and unlike impinging schemes to inject propellants tangentially along the chamber wall. Michaels called the subject injection scheme an Impinging Stream Vortex Chamber (ISVC). His preliminary tests showed that high performance, with an Isp efficiency of 9295, can be obtained. MSFC and the U. S. Army are jointly investigating an application of the ISVC concept for the cryogenic oxygen/hydrocarbon propellant system. This vortex chamber concept is currently tested with gel propellants at AMCOM at Redstone Arsenal, Alabama. A version of this concept for the liquid oxygen (LOX) hydrocarbon fuel (RP-1) system has been derived from the one for the gel propellant. An unlike impinging injector was employed to deliver the propellants to the chamber. MSFC is also conducting an alternative injection scheme, called the chasing injector, associated with this vortex chamber concept. In this injection technique, both propellant jets and their impingement point are in the same chamber cross-sectional plane. Long duration tests (approximately up to 15 seconds) will be conducted on the ISVC to study the thermal effects. This paper will report the progress of the subject efforts at NASA Marshall Space Flight Center. Thrust chamber performance and thermal wall compatibility will be evaluated. The chamber pressures, wall temperatures, and thrust will be measured as appropriate. The test data will be used to validate CFD models, which, in turn, will be used to design the optimum vortex chambers. Measurements in the previous tests showed that the chamber pressures vary significantly with radius. This is due to the existence of the vortices in the chamber flow field. Hence, the combustion efficiency may not be easily determined from chamber pressure. For this project, measured thrust data will be collected. The performance comparison will be in terms of specific impulse efficiencies. In addition to the thrust measurements, several pressure and temperature readings at various locations on the chamber head faceplate and the chamber wall will be made. The first injector and chamber were designed and fabricated based on the available data and experience gained during gel propellant system tests by the U.S. Army. The alternate injector for the ISVC was also fabricated. Hot-fire tests of the vortex chamber are about to start and are expected to complete in February of 2003 at the TS115 facility of MSFC.

Trinh, Huu P.↗
NASA NTRS2003

HART-II: Prediction of Blade-Vortex Interaction Loading

During the HART-I data analysis, the need for comprehensive wake data was found including vortex creation and aging, and its re-development after blade-vortex interaction. In October 2001, US Army AFDD, NASA Langley, German DLR, French ONERA and Dutch DNW performed the HART-II test as an international joint effort. The main objective was to focus on rotor wake measurement using a PIV technique along with the comprehensive data of blade deflections, airloads, and acoustics. Three prediction teams made preliminary correlation efforts with HART-II data: a joint US team of US Army AFDD and NASA Langley, German DLR, and French ONERA. The predicted results showed significant improvements over the HART-I predicted results, computed about several years ago, which indicated that there has been better understanding of complicated wake modeling in the comprehensive rotorcraft analysis. All three teams demonstrated satisfactory prediction capabilities, in general, though there were slight deviations of prediction accuracies for various disciplines.

Lim, Joon W.↗
NASA NTRS2003

Piloted Evaluation of Modernized Limited Authority Control Laws in the NASA-Ames Vertical Motion Simulator (VMS)

The UH-60 BLACK HAWK was designed in the 1970s, when the US Army primarily operated during the day in good visual conditions. Subsequently, the introduction of night-vision goggles increased the BLACK HAWK'S mission effectiveness, but the accident rate also increased. The increased accident rate is strongly tied to increased pilot workload as a result of a degradation in visual cues. Over twenty years of research in helicopter flight control and handling qualities has shown that these degraded handling qualities can be recovered by modifying the response type of the helicopter in low speed flight. Sikorsky Aircraft Corporation initiated a project under the National Rotorcraft Technology Center (NRTC) to develop modern flight control laws while utilizing the existing partial authority Stability Augmentation System (SAS) of the BLACK HAWK. This effort resulted in a set of Modernized Control Laws (MCLAWS) that incorporate rate command and attitude command response types. Sikorsky and the US Army Aeroflightdynamics Directorate (AFDD) conducted a piloted simulation on the NASA-Ames Vertical h4otion Simulator, to assess potential handling qualities and to reduce the risk of subsequent implementation and flight test of these modern control laws on AFDD's EH-60L helicopter. The simulation showed that Attitude Command Attitude Hold control laws in pitch and roll improve handling qualities in the low speed flight regime. These improvements are consistent across a range of mission task elements and for both good and degraded visual environments. The MCLAWS perform better than the baseline UH-60A control laws in the presence of wind and turbulence. Finally, while the improved handling qualities in the pitch and roll axis allow the pilot to pay more attention to the vertical axis and hence altitude performance also improves, it is clear from pilot comments and altitude excursions that the addition of an Altitude Hold function would further reduce workload and improve overall handling qualities of the aircraft.

Sahasrabudhe, Vineet↗
NASA NTRS1997

An Investigation to Improve Quality Evaluations of Primers and Propellant for 20mm Munitions

To reduce the frequency of electrically initiated, 20mm munition hangfires (delayed ignitions), a joint Army/NASA investigation was conducted to recommend quality evaluation improvements for acceptance of both primers and gun propellant. This effort focused only on evaluating ignition and combustion performance as potential causes of hangfires: poor electrical initiation of the primer, low output performance of the primer, low ignition sensitivity of the gun propellant, and the effects of cold temperature. The goal was to determine the "best" of the Army and NASA test methods to assess the functional performance of primers and gun propellants. The approach was to evaluate the performance of both high-quality and deliberately defective primers to challenge the sensitivity of test methods. In addition, the ignition sensitivity of different manufacturing batches of gun propellants was evaluated. The results of the investigation revealed that improvements can be made in functional evaluations that can assist in identifying and reducing ignition and performance variations. The "best" functional evaluation of primers and propellant is achieved through a combination of both Army and NASA test methods. Incorporating the recommendations offered in this report may provide for considerable savings in reducing the number of cartridge firings, while significantly lowering the rejection rate of primer, propellant and cartridge lots. The most probable causes for ignition and combustion-related hangfires were the lack of calcium silicide in the primer mix, a low output performance of primers, and finally, poor ignition sensitivity of gun propellant. Cold temperatures further reduce propellant ignition sensitivity, as well as reducing burn rate and chamber pressures.

Bement, L. J.↗
NASA NTRS1947

Data Obtained in the Flight Measurements to Determine the Stability and Control Characteristics of a C-54D Airplane (AAF No. 42-72713) and a Summary of the Test Program

The flight investigation of the C-54D airplane was initiated to determine the necessity of changes or additions to existing handling-qualities requirements to cove the case of instrument approaches with large airplanes. This paper gives a brief synopsis of the results and presents the measured data of tests to determine the stability and control characteristics. It was found that no new requirements were necessary to cover the problems of instrument approaches. The C-54D airplane tested met the Amy and Navy stability and control requirements except for the following items. The control-system friction with autopilot installed vas double that allowed by the requirements. The amount of friction was found to impair the controllability of the airplane in precision flying. The lateral and directional characteristics were good except that the maximum pb/2V was slightly below the minimum required, and the elevator-control forces to obtain the maximum pb/2V at low speeds were above the Army and Navy requirements. The longitudinal stability and control characteristics were good except that the elevator-control forces exceeded the limits of the Army and Navy requirements in turns and in landings. The stalling characteristics were considered good in all conditions with the stall warning in the form of tail buffeting occurring at speeds approximately 5 miles per hour above the stall.

Talmage, Donald B.↗
NASA NTRS1995

Code to Optimize Load Sharing of Split-Torque Transmissions Applied to the Comanche Helicopter

Most helicopters now in service have a transmission with a planetary design. Studies have shown that some helicopters would be lighter and more reliable if they had a transmission with a split-torque design instead. However, a split-torque design has never been used by a U.S. helicopter manufacturer because there has been no proven method to ensure equal sharing of the load among the multiple load paths. The Sikorsky/Boeing team has chosen to use a split-torque transmission for the U.S. Army's Comanche helicopter, and Sikorsky Aircraft is designing and manufacturing the transmission. To help reduce the technical risk of fielding this helicopter, NASA and the Army have done the research jointly in cooperation with Sikorsky Aircraft. A theory was developed that equal load sharing could be achieved by proper configuration of the geartrain, and a computer code was completed in-house at the NASA Lewis Research Center to calculate this optimal configuration.

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NASA NTRS2005

Face Gear Technology for Aerospace Power Transmission Progresses

The use of face gears in an advanced rotorcraft transmission design was first proposed by the McDonnell Douglas Helicopter Company during their contracted effort with the U.S. Army under the Advanced Rotorcraft Transmission (ART) program. Face gears would be used to turn the corner between the horizontal gas turbine engine and the vertical output rotor shaft--a function currently done by spiral bevel gears. This novel gearing arrangement would substantially lower the drive system weight partly because a face gear mesh would be used to split the input power between two output gears. However, the use of face gears and their ability to operate successfully at the speeds and loads required for an aerospace environment was unknown. Therefore a proof-of-concept phase with an existing test stand at the NASA Lewis Research Center was pursued. Hardware was designed that could be tested in Lewis' Spiral Bevel Gear Test Rig. The initial testing indicated that the face gear mesh was a feasible design that could be used at high speeds and load. Surface pitting fatigue was the typical failure mode, and that could lead to tooth fracture. An interim project was conducted to see if slight modifications to the gear tooth geometry or an alternative heat treating process could overcome the surface fatigue problems. From the initial and interim tests, it was apparent that for the surface fatigue problems to be overcome the manufacturing process used for this component would have to be developed to the level used for spiral bevel gears. The current state of the art for face gear manufacturing required using less than optimal gear materials and manufacturing techniques because the surface of the tooth form does not receive final finishing after heat treatment as it does for spiral bevel gears. This resulted in less than desirable surface hardness and manufacturing tolerances. An Advanced Research and Projects Agency (ARPA) Technology Reinvestment Project has been funded to investigate the effects of manufacturing process improvements on the operating characteristics of face gears. The program is being conducted with McDonnell Douglas Helicopter Co., Lucas Western Inc., the University of Illinois at Chicago, and a NASA/U.S. Army team. The goal of the project is develop the grinding process, experimentally verify the improvement in face gear fatigue life, and conduct a full-scale helicopter transmission test. The theory and methodology to grind face gears has been completed, and manufacture of the test hardware is ongoing. Experimental verification on test hardware is scheduled to begin in fiscal 1996.

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NASA NTRS1996

Study of Gear Dynamic Forces Completed

Gearbox-generated noise and vibration is objectionable in many vehicles, particularly helicopters. This noise excitation is caused by the load fluctuation as gear teeth enter and leave mesh. In high-quality gears, a common technique to reduce gear noise and vibration is to modify the tooth profile. Gear noise reduction is a NASA and U.S. Army goal, and a NASA/U.S. Army research project sponsored development of gear dynamics computer codes to help design quiet gears. As part of this project, a series of experiments was performed in the NASA Lewis Research Center's Gear Noise Rig to develop a data base of dynamic test data and to validate the predictions of the codes for several gear designs under a variety of test conditions.

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