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At least 379 records · Page 21

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NASA NTRS1996

Quantification of Gear Tooth Damage by Optimal Tracking of Vibration Signatures

This paper presents a technique for quantifying the wear or damage of gear teeth in a transmission system. The procedure developed in this study can be applied as a part of either an onboard machine health-monitoring system or a health diagnostic system used during regular maintenance. As the developed methodology is based on analysis of gearbox vibration under normal operating conditions, no shutdown or special modification of operating parameters is required during the diagnostic process. The process of quantifying the wear or damage of gear teeth requires a set of measured vibration data and a model of the gear mesh dynamics. An optimization problem is formulated to determine the profile of a time-varying mesh stiffness parameter for which the model output approximates the measured data. The resulting stiffness profile is then related to the level of gear tooth wear or damage. The procedure was applied to a data set generated artificially and to another obtained experimentally from a spiral bevel gear test rig. The results demonstrate the utility of the procedure as part of an overall health-monitoring system.

Choy, F. K.↗

NASA NTRS1996

Computerized Design and Analysis of Face-Milled, Uniform Tooth Height, Low-Noise Spiral Bevel Gear Drives

A new method for design and generation of spiral bevel gears of uniform tooth depth with localized bearing contact and low level of transmission errors is considered. The main features of the proposed approach are as follows: (1) the localization of the bearing contact is achieved by the mismatch of the generating surfaces. The bearing contact may be provided in the longitudinal direction, or in the direction across the surface; and (2) the low level of transmission errors is achieved due to application of nonlinear relations between the motions of the gear and the gear head-cutter. Such relations may be provided by application of a CNC machine. The generation of the pinion is based on application of linear relations between the motions of the tool and the pinion being generated. The relations described above permit a parabolic function of transmission errors to be obtained that is able to absorb almost linear functions caused by errors of gear alignment. A computer code has been written for the meshing and contact of the spiral bevel gears with the proposed geometry. The effect of misalignment on the proposed geometry has also been determined. Numerical examples for illustration of the proposed theory have been provided.

Litvin, F. L.↗

NASA NTRS1996

Balancing Dynamic Strength of Spur Gears Operated at Extended Center Distance

This paper presents an analytical study on using hob offset to balance the dynamic tooth strength of spur gears operated at a center distance greater than the standard value. This study is an extension of a static study by Mabie and others. The study was limited to the offset values that assure the pinion and gear teeth will neither be undercut nor become pointed. The analysis presented in this paper was performed using DANST-PC, a new version of the NASA gear dynamics code. The operating speed of the transmission influences the amount of hob offset required to equalize the dynamic stresses in the pinion and gear. The optimum hob offset for the pinion was found to vary within a small range as the speed changes. The optimum value is generally greater than the optimum value found by static procedures. For gears that must operate over a wide range of speeds, an average offset value may be used.

Lin, Hsiang Hsi↗

NASA NTRS1996

Dynamic Forces in Spur Gears - Measurement, Prediction, and Code Validation

Measured and computed values for dynamic loads in spur gears were compared to validate a new version of the NASA gear dynamics code DANST-PC. Strain gage data from six gear sets with different tooth profiles were processed to determine the dynamic forces acting between the gear teeth. Results demonstrate that the analysis code successfully simulates the dynamic behavior of the gears. Differences between analysis and experiment were less than 10 percent under most conditions.

Oswald, Fred B.↗

NASA NTRS1996

Computerized Design and Analysis of Face-Milled, Uniform Tooth Height, Low-Noise Spiral Bevel Gear Drives

A new method for design and generation of spiral bevel gears of uniform tooth depth with localized bearing contact and low level of transmission errors is considered. The main features of the proposed approach are as follows: (1) The localization of the bearing contact is achieved by the mismatch of the generating surfaces. The bearing contact may be provided in the longitudinal direction, or in the direction across the surface; and (2) The low level of transmission errors is achieved due to application of nonlinear relations between the motions of the gear and the gear head-cutter. Such relations may be provided by application of a CNC machine. The generation of the pinion is based on application of linear relations between the motions of the tool and the pinion being generated. The relations described above permit a parabolic function of transmission errors to be obtained that is able to absorb almost linear functions caused by errors of gear alignment. A computer code has been written for the meshing and contact of the spiral bevel gears with the proposed geometry. The effect of misalignment on the proposed geometry has also been determined. Numerical examples for illustration of the proposed theory have been provided.

Litvin, F. L.↗

NASA NTRS1997

Recent Advances in the Analysis of Spiral Bevel Gears

A review of recent progress for the analysis of spiral bevel gears will be described. The foundation of this work relies on the description of the gear geometry of face-milled spiral bevel gears via the approach developed by Litvin. This methodology was extended by combining the basic gear design data with the manufactured surfaces using a differential geometry approach, and provides the data necessary for assembling three-dimensional finite element models. The finite element models have been utilized to conduct thermal and structural analysis of the gear system. Examples of the methods developed for thermal and structural/contact analysis are presented.

Handschuh, Robert F.↗

NASA NTRS1999

Modeling and Validation of a Navy A6-Intruder Actively Controlled Landing Gear System

Concepts for long-range air travel are characterized by airframe designs with long, slender, relatively flexible fuselages. One aspect often overlooked is ground-induced vibration of these aircraft. This paper presents an analytical and experimental study of reducing ground-induced aircraft vibration loads by using actively controlled landing gear. A facility has been developed to test various active landing gear control concepts and their performance, The facility uses a Navy A6 Intruder landing gear fitted with an auxiliary hydraulic supply electronically controlled by servo valves. An analytical model of the gear is presented, including modifications to actuate the gear externally, and test data are used to validate the model. The control design is described and closed-loop test and analysis comparisons are presented.

Horta, Lucas G.↗

NASA NTRS1999

An Overview of Landing Gear Dynamics

One of the problems facing the aircraft community is landing gear dynamics, especially shimmy and brake-induced vibration. Shimmy and brake-induced vibrations can lead to accidents due to excessive wear and shortened life of gear parts and contribute to pilot and passenger discomfort. To increase understanding of these problems, a literature survey was performed. The major focus is on work from the last ten years. Some older publications are included to understand the longevity of the problem and the background from earlier researchers. The literature survey includes analyses, testing, modeling, and simulation of aircraft landing gear; and experimental validation and characterization of shimmy and brake-induced vibration of aircraft landing gear. The paper presents an overview of the problem, background information, and a history of landing gear dynamics problems and solutions. Based on the survey an assessment and recommendations of the most critically needed enhancements to the state of the art will be presented. The status of Langley work contributing to this activity will be given.

Pritchard, Jocelyn I.↗

NASA NTRS1999

Actively Controlled Landing Gear for Aircraft Vibration Reduction

Concepts for long-range air travel are characterized by airframe designs with long, slender, relatively flexible fuselages. One aspect often overlooked is ground induced vibration of these aircraft. This paper presents an analytical and experimental study of reducing ground-induced aircraft vibration loads using actively controlled landing gears. A facility has been developed to test various active landing gear control concepts and their performance. The facility uses a NAVY A6-intruder landing gear fitted with an auxiliary hydraulic supply electronically controlled by servo valves. An analytical model of the gear is presented including modifications to actuate the gear externally and test data is used to validate the model. The control design is described and closed-loop test and analysis comparisons are presented.

Horta, Lucas G.↗

NASA NTRS1999

Video Imaging System Particularly Suited for Dynamic Gear Inspection

A digital video imaging system that captures the image of a single tooth of interest of a rotating gear is disclosed. The video imaging system detects the complete rotation of the gear and divide that rotation into discrete time intervals so that each tooth of interest of the gear is precisely determined when it is at a desired location that is illuminated in unison with a digital video camera so as to record a single digital image for each tooth. The digital images are available to provide instantaneous analysis of the tooth of interest, or to be stored and later provide images that yield a history that may be used to predict gear failure, such as gear fatigue. The imaging system is completely automated by a controlling program so that it may run for several days acquiring images without supervision from the user.

Broughton, Howard↗

NASA NTRS2000

Simulating Fatigue Crack Growth in Spiral Bevel Gears

The majority of helicopter transmission systems utilize spiral bevel gears to convert the horizontal power from the engine into vertical power for the rotor. Due to the cyclical loading on a gear's tooth, fatigue crack propagation can occur. In rotorcraft applications, a crack's trajectory determines whether the gear failure will be benign or catastrophic for the aircraft. As a result, the capability to predict crack growth in gears is significant. A spiral bevel gear's complex shape requires a three dimensional model of the geometry and cracks. The boundary element method in conjunction with linear elastic fracture mechanics theories is used to predict arbitrarily shaped three dimensional fatigue crack trajectories in a spiral bevel pinion under moving load conditions. The predictions are validated by comparison to experimental results. The sensitivity of the predictions to variations in loading conditions and crack growth rate model parameters is explored. Critical areas that must be understood in greater detail prior to predicting more accurate crack trajectories and crack growth rates in three dimensions are identified.

Spievak, Lisa E.↗

NASA NTRS2000

Influence of Tooth Spacing Error on Gears With and Without Profile Modifications

A computer simulation was conducted to investigate the effectiveness of profile modification for reducing dynamic loads in gears with different tooth spacing errors. The simulation examined varying amplitudes of spacing error and differences in the span of teeth over which the error occurs. The modification considered included both linear and parabolic tip relief. The analysis considered spacing error that varies around most of the gear circumference (similar to a typical sinusoidal error pattern) as well as a shorter span of spacing errors that occurs on only a few teeth. The dynamic analysis was performed using a revised version of a NASA gear dynamics code, modified to add tooth spacing errors to the analysis. Results obtained from the investigation show that linear tip relief is more effective in reducing dynamic loads on gears with small spacing errors but parabolic tip relief becomes more effective as the amplitude of spacing error increases. In addition, the parabolic modification is more effective for the more severe error case where the error is spread over a longer span of teeth. The findings of this study can be used to design robust tooth profile modification for improving dynamic performance of gear sets with different tooth spacing errors.

Padmasolala, Giri↗

NASA NTRS2003

Effects on Diagnostic Parameters After Removing Additional Synchronous Gear Meshes

Gear cracks are typically difficult to diagnose with sufficient time before catastrophic damage occurs. Significant damage must be present before algorithms appear to be able to detect the damage. Frequently there are multiple gear meshes on a single shaft. Since they are all synchronous with the shaft frequency, the commonly used synchronous averaging technique is ineffective in removing other gear mesh effects. Carefully applying a filter to these extraneous gear mesh frequencies can reduce the overall vibration signal and increase the accuracy of commonly used vibration metrics. The vibration signals from three seeded fault tests were analyzed using this filtering procedure. Both the filtered and unfiltered vibration signals were then analyzed using commonly used fault detection metrics and compared. The tests were conducted on aerospace quality spur gears in a test rig. The tests were conducted at speeds ranging from 2500 to 5000 revolutions per minute and torques from 184 to 228 percent of design load. The inability to detect these cracks with high confidence results from the high loading which is causing fast fracture as opposed to stable crack growth. The results indicate that these techniques do not currently produce an indication of damage that significantly exceeds experimental scatter.

Decker, Harry J.↗

NASA NTRS2004

Investigation of Gear and Bearing Fatigue Damage Using Debris Particle Distributions

A diagnostic tool was developed for detecting fatigue damage to spur gears, spiral bevel gears, and rolling element bearings. This diagnostic tool was developed and evaluated experimentally by collecting oil debris data from fatigue tests performed in the NASA Glenn Spur Gear Fatigue Rig, Spiral Bevel Gear Test Facility, and the 500hp Helicopter Transmission Test Stand. During each test, data from an online, in-line, inductance type oil debris sensor was monitored and recorded for the occurrence of pitting damage. Results indicate oil debris alone cannot discriminate between bearing and gear fatigue damage.

Dempsey, Paula J.↗

NASA NTRS2005

Face Gear Drive With Helical Involute Pinion: Geometry, Generation by a Shaper and a Worm, Avoidance of Singularities and Stress Analysis

A new type of face-gear drive with intersected axes of rotation formed by a helical involute pinion and conjugated face-gear has been investigated. Generation of face-gears by a shaper free of undercutting and pointing has been investigated. A new method of grinding or cutting of face-gears by a worm of special shape has been developed. A computerized design procedure has been developed to avoid undercutting and pointing by a shaper or by a generating worm. Also, a method to determine the limitations of the helix angle magnitude has been developed. The method provides a localization of the bearing contact to reduce the shift of bearing contact caused by misalignment. The analytical method provides a simulation of the meshing and contact of misaligned gear drives. An automatic mesh generation method has been developed and used to conduct a 3D contact stress analysis of several teeth. The theory developed is illustrated with several examples.

Litvin, Faydor L.↗

NASA NTRS2001

Vapor/Mist Used to Lubricate Gears After Loss of Primary Lubrication System

Loss of lubrication in rotorcraft drive systems is a demanding requirement placed on drive system manufacturers. The drive system must operate for at least 30 minutes once the primary lubrication system has failed. This test is a military requirement that must be passed prior to certification of the aircraft. As new aircraft engines, operating at higher speeds, are fielded, the requirements for the drive system become increasingly more difficult. Also, the drive system must be lightweight, which minimizes the opportunity to use the gear bodies to absorb the tremendous amount of heating that takes place. In many cases, the amount of heat generated because of the high speed and load requires an emergency lubrication system that negatively impacts the aircraft's weight, complexity, and cost. A single mesh spur gear test rig is being used at the NASA Glenn Research Center to investigate possible emergency lubrication system improvements that will minimize the impact of having these systems onboard rotorcraft. A technique currently being investigated uses a vapor/mist system to lubricate the contacting surfaces after the primary lubrication system has been shut down. A number of tests were conducted in which the vapor/mist used the same lubricant as the primary system, but at a greatly reduced flow rate. Each test was initiated with the primary lubrication system operational and at steady-state conditions for a given speed and load. Then the primary lubrication system was shut down, and the vapor/mist lubrication system was initiated. An example of the tests conducted is shown in the figures. These preliminary tests have uncovered a mechanism that provides a lubricious, carbonaceous solid on the surface that actually reduces the surface temperature of the meshing gear teeth during operation. Surface analysis of the carbonaceous solid revealed it was graphitic. This mechanism is the synthetic lubricant "coking" on the active profile of the gears, which reduces the friction between the contacting gear surfaces. The level of load affects the onset of this mechanism: the higher the load, the sooner coking takes place. Future work will investigate several other factors that could improve the already promising results that have been attained.

Handschuh, Robert F.↗

NASA NTRS2002

Gear Transmission Error Measurement System Made Operational

A system directly measuring the transmission error between the meshing spur or helical gears was installed at the NASA Glenn Research Center and made operational in August 2001. This system employs light beams directed by lenses and prisms through gratings mounted on the two gear shafts. The amount of light that passes through both gratings is directly proportional to the transmission error of the gears. The device is capable of resolution better than 0.1 mm (one thousandth the thickness of a human hair). The measured transmission error can be displayed in a "map" that shows how the transmission error varies with the gear rotation or it can be converted to spectra to show the components at the meshing frequencies. Accurate transmission error data will help researchers better understand the mechanisms that cause gear noise and vibration and will lead to The Design Unit at the University of Newcastle in England specifically designed the new system for NASA. It is the only device in the United States that can measure dynamic transmission error at high rotational speeds. The new system will be used to develop new techniques to reduce dynamic transmission error along with the resulting noise and vibration of aeronautical transmissions.

Oswald, Fred B.↗

NASA NTRS2005

Investigations of Shuttle Main Landing Gear Door Environmental Seals

The environmental seals for the main landing gear doors of the Shuttle Orbiters were raised by the Columbia Accident Investigation Board as a potential safety concern. Inspections of seals installed on the Shuttle Discovery revealed that they were permanently deformed and no longer met certified seal compression requirements. Replacement of the seals led to the inability to fully close the main landing gear doors. Johnson Space Center requested that Glenn Research Center conduct tests on the main landing gear door environmental seals to assist in installing the seals in a manner to allow the main landing gear doors to fully close. Further testing was conducted to fill out the seal performance database. Results from the testing indicated that the method of bonding the seals was important in reducing seal loads on the main landing gear doors. Also, the replacement seals installed in Shuttle Discovery were found to have leakage performance sufficient to meet the certification requirements.

Finkbeiner, Joshua↗