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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 217 records · Page 12

All sources NASA NTRS DOE OSTI

NASA NTRS1993

Evaluation of a vibration diagnostic system for the detection of spur gear pitting failures

A vibration diagnostic system was used to detect spur gear surface pitting fatigue in a closed-loop spur gear fatigue test rig. The diagnostic system, comprising a personal computer with an analog-to-digital conversion board, a diagnostic system unit, and software, uses time-synchronous averaging of the vibration signal to produce a vibration image of each tooth on any gear in a transmission. Several parameters were analyzed including gear pair stress wave and raw baseband vibration, kurtosis, peak ratios, and others. The system provides limits for the various parameters and gives a warning when the limits are exceeded. Several spur gear tests were conducted with this system and vibration data analyzed at 5-min. intervals. The results presented herein show that the system is fairly effective at detecting spur gear tooth surface fatigue pitting failures.

Townsend, Dennis P.↗

NASA NTRS1976

Quiet Clean Short-haul Experimental Engine (QCSEE): Hamilton Standard cam/harmonic drive variable pitch fan actuation system detail design report

A variable pitch fan actuation system was designed which incorporates a remote nacelle-mounted blade angle regulator. The regulator drives a rotating fan-mounted mechanical actuator through a flexible shaft and differential gear train. The actuator incorporates a high ratio harmonic drive attached to a multitrack spherical cam which changes blade pitch through individual cam follower arms attached to each blade trunnion. Detail design parameters of the actuation system are presented. These include the following: design philosophies, operating limits, mechanical, hydraulic and thermal characteristics, mechanical efficiencies, materials, weights, lubrication, stress analyses, reliability and failure analyses.

Source record↗

NASA NTRS1976

Quiet Clean Short-haul Experimental Engine (QCSEE) whirl test of cam/harmonic pitch change actuation system

A variable pitch fan actuation system, which incorporates a remote nacelle mounted blade angle regulator, was tested. The regulator drives a rotating fan mounted mechanical actuator through a flexible shaft and differential gear train. The actuator incorporates a high ratio harmonic drive attached to a multitrack spherical cam which changes blade pitch through individual cam follower arms attached to each blade trunnion. Testing of the actuator on a whirl rig, is reported. Results of tests conducted to verify that the unit satisfied the design requirements and was structurally adequate for use in an engine test are presented.

Source record↗

NASA NTRS2005

The Influence of Roughness on Gear Surface Fatigue

Gear working surfaces are subjected to repeated rolling and sliding contacts, and often designs require loads sufficient to cause eventual fatigue of the surface. This research provides experimental data and analytical tools to further the understanding of the causal relationship of gear surface roughness to surface fatigue. The research included evaluations and developments of statistical tools for gear fatigue data, experimental evaluation of the surface fatigue lives of superfinished gears with a near-mirror quality, and evaluations of the experiments by analytical methods and surface inspections. Alternative statistical methods were evaluated using Monte Carlo studies leading to a final recommendation to describe gear fatigue data using a Weibull distribution, maximum likelihood estimates of shape and scale parameters, and a presumed zero-valued location parameter. A new method was developed for comparing two datasets by extending the current methods of likelihood-ratio based statistics. The surface fatigue lives of superfinished gears were evaluated by carefully controlled experiments, and it is shown conclusively that superfinishing of gears can provide for significantly greater lives relative to ground gears. The measured life improvement was approximately a factor of five. To assist with application of this finding to products, the experimental condition was evaluated. The fatigue life results were expressed in terms of specific film thickness and shown to be consistent with bearing data. Elastohydrodynamic and stress analyses were completed to relate the stress condition to fatigue. Smooth-surface models do not adequately explain the improved fatigue lives. Based on analyses using a rough surface model, it is concluded that the improved fatigue lives of superfinished gears is due to a reduced rate of near-surface micropitting fatigue processes, not due to any reduced rate of spalling (sub-surface) fatigue processes. To complete the evaluations, surface inspection were completed. The surface topographies of the ground gears changed substantially due to running, but the topographies of the superfinished gears were essentially unchanged with running.

Krantz, Timothy↗

NASA NTRS2003

Ultra High Bypass Ratio Low Noise Engine Study

A study was conducted to identify engine cycle and technologies needed for a regional aircraft which could be capable of achieving a 10 EPNdB reduction in community noise level relative to current FAR36 Stage 3 limits. The study was directed toward 100-passenger regional aircraft with engine configurations in the 15,000 pound thrust class. The study focused on Ultra High Bypass Ratio (UHBR) cycles due to low exhaust jet velocities and reduced fan tip speeds. The baseline engine for this study employed a gear-driven, 1000 ft/sec tip speed fan and had a cruise bypass ratio of 14:1. A revised engine configuration employing fan and turbine design improvements are predicted to be 9.2 dB below current takeoff limits and 12.8 dB below current approach limits. An economic analysis was also done by estimating Direct Operating Cost (DOC).

Dalton, W. N., III↗

NASA NTRS2017

Cryo-Gearbox Using Bulk Metallic Glasses

Harmonic drives are a highly efficient and compact gearing technology that are widely used in robotics and aerospace applications (e.g. Mars Science Lab) due to their excellent torque-to-mass ratio, low backlash, and high positional accuracy. One major problem using any gearing on other planetary bodies is the need for heaters to keep the gearbox from freezing. Currently the Mars Science Lab uses 40% of its daily power output to operate heaters to keep the grease in the gearboxes from freezing. Also wear can limit the lifetime and performance of these systems. One possible solution to this problem could be to use a relatively new material known as Bulk Metallic Glasses (BMGs, also known as Amorphous Metals). BMGs are non-crystalline metallic alloys that exhibit superior mechanical properties. Compared to modern aerospace steels BMGs have a higher strength, higher elastic limit, and lower density. BMGs used in harmonic drives (especially the flex spline) could lead to longer system lifetimes, lower mass, and increased performance. Jet Propulsion Laboratory (JPL) is researching a new method of manufacturing the flex spline by injection molding and is hoping to have reduced costs as well as the benefits listed above. In conjunction with Kennedy Space Center (KSC), JPL is providing gearboxes that KSC will test greaseless in an extreme environment. KSC has completed the assembly and checkout of a test stand that is capable of testing a gearbox in a vacuum of less than 2 milli torr, 100 Kelvin temperature, 250 Nm of load, input and output torque measurements and 120 RPM input speed.

Drew Smith↗

NASA NTRS1976

Some applications of the NASTRAN level 16 subsonic flutter analysis capability

The Level 16 flutter analysis capability was applied to an aspect-ratio-6.8 subsonic transport type wing, an aspect-ratio-1.7 arrow wing, and an aspect-ratio-1.3 all movable horizontal tail with a geared elevator. The transport wing and arrow wing results are compared with experimental results obtained in the Langley transonic dynamic tunnel and with other calculated results obtained using subsonic lifting surface (kernel function) unsteady aerodynamic theory.

Doggett, R. V., Jr.↗

NASA NTRS1979

Low-speed aerodynamic performance of a high-aspect-ratio supercritical-wing transport model equipped with full-span slat and part-span double-slotted flaps

An investigation was conducted in the Langley V/STOL tunnel to determine the static longitudinal and lateral-directional aerodynamic characteristics of an advanced high-aspect-ratio supercritical-wing transport model equipped with a full-span leading-edge slat and part-span double-slotted trailing-edge flaps. This wide-body transport model was also equipped with spoiler and aileron control surfaces, flow-through nacelles, landing gear, movable horizontal tails, and interchangeable wing tips with aspect ratios of 10 and 12. The model was tested with leading-edge slat and trailing-edge flap combinations representative of cruise, climb, takeoff, and landing wing configurations. The tests were conducted at free-stream conditions corresponding to Reynolds numbers (based on mean geometric chord) of 0.97 to 1.63 x 10 to the 6th power and corresponding Mach numbers of 0.12 to 0.20, through an angle-of-attack range of -2 deg to 24 deg and a sideslip-angle range of -10 deg to 5 deg.

Morgan, H. L., Jr.↗

NASA NTRS2000

Handbook on Face Gear Drives with a Spur Involute Pinion

The use of face gears in power transmission and drive systems has a significant number of benefits. Face gears allow a variety of new transmission arrangements as well as high reduction ratio capability. This leads to drive system weight reduction and improvements in performance. In this work, basic information about the design and analysis of face gear drives is presented. The work considers face gears in mesh with spur involute pinions for both intersecting axes and offset drives. Tooth geometry, kinematics, generation of face gears with localized bearing contact by cutting and grinding, avoidance of tooth undercutting, avoidance of tooth pointing, tooth contact analysis, and algorithms for the simulation of meshing and contact arc all topics which are discussed. In addition, applications of face gear drives are presented. Included are design uses in aerospace applications such as helicopter transmissions, split-torque face gear arrangements, comparisons of face gears with bevel gears, and general design considerations.

Litvin, F. L.↗

NASA NTRS2012

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.↗

NASA NTRS2014

Offset Compound Gear Inline Two-Speed Drive

Stevens, Mark A.↗

NASA NTRS2012

Multi-Objective Optimization of a Turbofan for an Advanced, Single-Aisle Transport

Considerable interest surrounds the design of the next generation of single-aisle commercial transports in the Boeing 737 and Airbus A320 class. Aircraft designers will depend on advanced, next-generation turbofan engines to power these airplanes. The focus of this study is to apply single- and multi-objective optimization algorithms to the conceptual design of ultrahigh bypass turbofan engines for this class of aircraft, using NASA s Subsonic Fixed Wing Project metrics as multidisciplinary objectives for optimization. The independent design variables investigated include three continuous variables: sea level static thrust, wing reference area, and aerodynamic design point fan pressure ratio, and four discrete variables: overall pressure ratio, fan drive system architecture (i.e., direct- or gear-driven), bypass nozzle architecture (i.e., fixed- or variable geometry), and the high- and low-pressure compressor work split. Ramp weight, fuel burn, noise, and emissions are the parameters treated as dependent objective functions. These optimized solutions provide insight to the ultrahigh bypass engine design process and provide information to NASA program management to help guide its technology development efforts.

Berton, Jeffrey J.↗

NASA NTRS2015

Gear Tooth Root Stresses of a Very Heavily Loaded Gear Pair-Case Study: Orbiter Body Flap Actuator Pinion and Ring Gear

The space shuttle orbiter's body flap actuator gearing was assessed as a case study of the stresses for very heavily loaded external-internal gear pairs (meshing pinion and ring gear). For many applications, using the high point of single tooth contact (HPSTC) to locate the position of the tooth force is adequate for assessing the maximum tooth root stress condition. But for aerospace gearing such an approach may be inadequate for assessing the stress condition while also simultaneously minimizing mass. In this work specialized contact analyses and finite element methods were used to study gear tooth stresses of body flap actuator gears. The analytical solutions considered the elastic deformations as an inherent part of the solutions. The ratio for the maximum tooth stresses using the HPSTC approach solutions relative to the contact analysis and finite element solutions were 1.40 for the ring gear and 1.28 for the pinion gear.

finite element method↗

NASA NTRS1990

Assessment of worm gearing for helicopter transmissions

A high-efficiency hydrostatic worm gear drive for helicopter transmissions is assessed. The example given is for a large cargo helicopter with three 4000-kW engines and transmission reduction ratio of 110. Also contained are: an efficiency calculation, a description of the test stand for evaluating the feasibility of worm gear hydrostatic mesh, a weight calculation, and a comparison with conventional helicopter transmissions of the same power and transmission reduction ratio.

Chaiko, Lev↗

NASA NTRS1980

Parametric tests of a traction drive retrofitted to an automotive gas turbine

The results of a test program to retrofit a high performance fixed ratio Nasvytis Multiroller Traction Drive in place of a helical gear set to a gas turbine engine are presented. Parametric tests up to a maximum engine power turbine speed of 45,500 rpm and to a power level of 11 kW were conducted. Comparisons were made to similar drives that were parametrically tested on a back-to-back test stand. The drive showed good compatibility with the gas turbine engine. Specific fuel consumption of the engine with the traction drive speed reducer installed was comparable to the original helical gearset equipped engine.

Rohn, D. A.↗

NASA NTRS1994

Measurements of Forward Flight Effects on the Advanced Ducted Propulsion Demonstrator Engine

The performance of the Pratt & Whitney Advanced Ducted Propulsion (ADP) UHB concept has been recently evaluated with studies of a 17 in. diameter fan simulator. Following the model scale tests, a 118 in. diameter demonstrator was tested at the NASA Ames 40- by 80-Foot Wind Tunnel. The 18 blade fan was driven by the low compressor shaft of a PW2037 core through a reduction gear system fabricated by Fiat with approximately 1:3.7 reduction ratio. ne variable pitch fan was hydraulically actuated with settings for take-off, cruise, feather, and reverse thrust. The low-pressure turbine was built by MTU to provide higher shaft power in comparison with the standard PW2037. The demonstrator was provided with 45 vanes located 2.6 fan chords downstream of the rotor, and 10 case struts approximately 1 fan chord downstream of the vanes. The inlet, mid-duct, and exhaust linings were acoustically treated. Acoustic surveys were taken in the for-ward thrust mode for fan speeds of 898, 1120, 1205, and 1302 R.P.M., and at tunnel speeds of 25, 50, 100, and 140 kts. The lowest speed was achieved with the wind tunnel fans at flat pitch, but with the engine pumping the test section Microphone signals were recorded for 30 seconds at 5 deg. increments. These measurements will be used to assess the effects of forward speed on UHB engines, to compare these effects with the corresponding characteristics of conventional bypass ratio engines, and to discuss the various aspects of testing large engines in the wind tunnel.

Horne, W. C.↗

NASA NTRS1939

Engine Operation in Flight for Minimum Fuel Consumption

Engine and airplane performance data have been gathered from various sources and analyzed to determine indications of the most economical methods of flight operation from a consideration of fuel expenditure. The analysis includes the influence of such facts as fuel-air ratio, engine speed, engine knock, altitude, cylinder cooling, spark timing, and limits of cruising brake mean effective pressure. The results indicate that the cheapest power is obtained with approximately correct mixture at low engine speed and highest permissible manifold pressure. If more power is desired, the methods of obtaining it are, in order of fuel economy: (a) increasing the engine speed and maintaining safe cylinder temperatures by cooling; (b) retarding the spark or cooling further to permit higher manifold pressure; and, (c) riching the mixture. The analysis further shows that the maximum time endurance of flight occurs at the air speed corresponding to minimum thrust horsepower required and with minimum practicable engine speed. Maximum mileage per pound of fuel is obtained at slightly higher air speed. The fuel-air ratio should be approximately the theoretically correct ratio in both cases. For an engine equipped with a geared supercharger, as in the example presented, and with knock as the limiting condition, a comparison of operation at sea level and at 6,000 feet shoes flight at altitude to be more economical on the basis of both range and endurance.

Reuter, George↗

NASA NTRS2018

Design Space Exploration of Pericyclic Transmission with Counterbalance and Bearing Load Analysis

The pericyclic transmission provides the opportunity to vastly impact transmission design in rotorcraft due to its ability to provide exceedingly high reduction ratios in a single stage that would normally require multiple gear stages to produce. This could lead to lighter transmissions with fewer components, increased range, reliability, efficiency, speed and decreased cost to maintain. While many previous studies have focused upon the gearing within the pericyclic transmission, this work focused on what influences pericyclic geometry, and how changes in geometry impacts bearing loads. Specifically the loading of bearings that must deliver power from the input shaft to the nutating and rotating gears of the system were of primary concern. A comprehensive look at dynamic loads generated by nutating bodies was performed. Methods to address these dynamic loads via application of counterbalances and deviation from conventional pericyclic transmission designs were utilized to negate the dynamic moment of concern. Finally a static solver was used to determine the bearing loads with updated component geometries and mass moment of inertias that included the required counterbalances.

Pericyclic↗