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At least 163 records · Page 9

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NASA NTRS1989

An investigation of gear mesh failure prediction techniques

A study was performed in which several gear failure prediction methods were investigated and applied to experimental data from a gear fatigue test apparatus. The primary objective was to provide a baseline understanding of the prediction methods and to evaluate their diagnostic capabilities. The methods investigated use the signal average in both the time and frequency domain to detect gear failure. Data from eleven gear fatigue tests were recorded at periodic time intervals as the gears were run from initiation to failure. Four major failure modes, consisting of heavy wear, tooth breakage, single pits, and distributed pitting were observed among the failed gears. Results show that the prediction methods were able to detect only those gear failures which involved heavy wear or distributed pitting. None of the methods could predict fatigue cracks, which resulted in tooth breakage, or single pits. It is suspected that the fatigue cracks were not detected because of limitations in data acquisition rather than in methodology. Additionally, the frequency response between the gear shaft and the transducer was found to significantly affect the vibration signal. The specific frequencies affected were filtered out of the signal average prior to application of the methods.

Zakrajsek, James J.↗

NASA NTRS1990

Surface pitting fatigue life of noninvolute, low-contact-ratio gears

Spur gear endurance tests were conducted to investigate the surface pitting fatigue life of noninvolute gears with low numbers of teeth and low contact ratios for use in advanced applications. The results were compared with those for a standard involute design with a low number of teeth. The gear pitch diameter was 8.89 cm (3.50 in.) with 12 teeth on both gear designs. Test conditions were an oil inlet temperature of 320 K (116 F), an oil outlet temperature of 350 K (170 F), a maximum Hertz stress of 1.49 GPa (216 ksi), and a speed of 10 000 rpm. The following results were obtained: the noninvolute gear had a surface pitting fatigue life approximately 1.6 times that of the standard involute gear of a similar design; and the surface pitting fatigue life of the 3.43-pitch AISI 8620 noninvolute gear was approximately equal to the surface pitting fatigue life of an 8-pitch, 28-tooth AISI 9310 gear at the same load but at a considerably higher maximum Hertz stress.

Townsend, Dennis P.↗

NASA NTRS1989

Profile modification to minimize spur gear dynamic loading

An analytical computer simulation program for dynamic modeling of low-contact-ratio spur gear systems is presented. The procedure computes the static transmission error of the gears operating under load and uses a fast Fourier transform to generate the frequency spectrum of the static transmission error at various tooth profile modifications. The dynamic loading response of an unmodified (perfect involute) gear pair was compared with that of gears with various profile modifications. Correlations were found between various profile modifications and the resulting dynamic loads. An effective error, obtained from frequency domain analysis of the static transmission error of the gears, gave a very good indication of the optimum profile modification to reduce gear dynamic loading. Design curves generated by dynamic simulation at various profile modifications are given for gear systems operated at various loads. Optimum profile modifications can be determined from these design curves for improved gear design.

Lin, H. H.↗

NASA NTRS1990

Surface pitting fatigue life of noninvolute, low-contact-ratio gears

Spur gear endurance tests were conducted to investigate the surface pitting fatigue life of noninvolute gears with low numbers of teeth and low contact ratios for use in advanced applications. The results were compared with those for a standard involute design with a low number of teeth. The gear pitch diameter was 8.89 cm (3.50 in.) with 12 teeth on both gear designs. Test conditions were an oil inlet temperature of 320 K (116 F), an oil outlet temperature of 350 K (170 F), a maximum Hertz stress of 1.49 GPa (216 ksi), and a speed of 10,000 rpm. The following results were obtained: the noninvolute gear had a surface pitting fatigue life approximately 1.6 times that of the standard involute gear of a similar design; and the surface pitting fatigue life of the 3.43-pitch AISI 8620 noninvolute gear was approximately equal to the surface pitting fatigue life of an 8-pitch, 28-tooth AISI 9310 gear at the same load but at a considerably higher maximum Hertz stress.

Townsend, Dennis P.↗

NASA NTRS1990

Non-linear dynamic analysis of geared systems

Under driving conditions, a typical geared system may be subjected to large dynamic loads. Also, the vibration level of the geared system is directly related to the noise radiated from the gear box. The steady state dynamic behavior of the system is examined in order to design reliable and quiet transmissions. The scope is limited to a system containing a spur gear pair with backlash and periodically time varying mesh stiffness, and rolling element bearings with clearance type nonlinearities. The internal static transmission error at the gear mesh, which is of importance from high frequency noise and vibration control view point, is considered in the formulation in sinusoidal or periodic form. A dynamic finite element model of the linear time invariant (LTI) system is developed. Effects of several system parameters, such as torsional and transverse flexibilities of the shafts and prime mover/load inertias, on free and forced vibration characteristics are investigated. Several reduced order LTI models are developed and validated by comparing their eigen solutions with the finite element model results. Using the reduced order formulations, a three degree of freedom dynamic model is developed which includes nonlinearities associated with radical clearances in the radial rolling element bearings, backlash between a spur gear pair and periodically varying gear mesh stiffness. As a limiting case, a single degree of freedom model of the spur gear pair with backlash is considered and mathematical conditions for tooth separation and back collision are defined. Both digital simulation technique and analytical models such as method of harmonic balance and the method of multiple scales were used to develop the steady state frequency response characteristics for various nonlinear and/or time varying cases.

Singh, Rajendra↗

NASA NTRS1991

Evaluation of advanced lubricants for aircraft applications using gear surface fatigue tests

Surface pitting fatigue life tests were conducted with five lubricants, using spur gears made from a single lot of consumable-electrode vacuum melted (CVM) AISI 9310 steel. The gears were case carbonized and hardened to a Rockwell c-60 and finish ground. The gear pitch diameter was 8.89 cm. The lot of gears was divided into five groups, each of which was tested with a different lubricant. The test lubricants can be classified as synthetic polyol-esters with various viscosities and additive packages. Test conditions included bulk gear temperature of 350 K, a maximum Hertz stress of 1.71 GPa (248 ksi) at the pitch line, and a speed of 10,000 RPM. The lubricant with a viscosity that provided a specific film thickness greater than one and with an additive package produced far greater gear surface fatigue lives than lubricants with a viscosity that provided specific film thickness less than one. A low viscosity lubricant with an additive package produced gear surface fatigue lives equivalent to a similar base stock lubricant with 30 percent higher viscosity, but without an additive package. Lubricants with the same viscosity and similar additive packages gave equivalent gear surface fatigue lives.

Townsend, Dennis P.↗

NASA NTRS1991

Harmonic drive gear error: Characterization and compensation for precision pointing and tracking

Imperfections and geometry effects in harmonic drive gear reducers cause a cyclic gear error, which at a systems level, results in high frequency torque fluctuations. To address this problem, gear error testing was performed on a wide variety of sizes and types of harmonic drives. It was found that although all harmonic drives exhibit a significant first harmonic, higher harmonics varied greatly with each unit. From life tests, small changes were found in harmonic content, phase shift, and error magnitude (on the order of .008 deg peak-to-peak maximum) occurred for drives with many millions of degrees of output travel. Temperature variations also influenced gear error. Over a spread of approximately 56 C (100 F), the error varied in magnitude approximately 20 percent but changes in a repeatable and predictable manner. Concentricity and parallelness tests of harmonic drive parts resulted in showing alignment influence gear error amplitude. Tests on dedoidaled harmonic drives showed little effect on gear error; surprisingly, in one case for a small drive, gear error actually improved. Electronic compensation of gear error in harmonic drives was shown to be substantially effective for units that are first harmonic dominant.

Nye, Ted W.↗

NASA NTRS1991

Evaluation of advanced lubricants for aircraft applications using gear surface fatigue tests

Townsend, Dennis P.↗

NASA NTRS1992

Improvement in surface fatigue life of hardened gears by high-intensity shot peening

Two groups of carburized, hardened, and ground spur gears that were manufactured from the same heat vacuum induction melted vacuum arc melted (VIM VAR) AISI 9310 steel were endurance tested for surface fatigue. Both groups were manufactured with a standard ground 16 rms surface finish. One group was subjected to a shot peening (SP) intensity of 7 to 9A, and the second group was subjected to a SP intensity of 15 to 17A. All gears were honed after SP to a surface finish of 16 rms. The gear pitch diameter was 8.89 cm. Test conditions were a maximum Hertz stress of 1.71 GPa, a gear temperature of 350 K, and a speed of 10000 rpm. The lubricant used for the tests was a synthetic paraffinic oil with an additive package. The following results were obtained: The 10 pct. surface fatigue (pitting) life of the high intensity (15 to 17A) SPed gears was 2.15 times that of the medium intensity (7 to 9A) SPed gears, the same as that calculated from measured residual stress at a depth of 127 microns. The measured residual stress for the high intensity SPed gears was 57 pct. higher than that for the medium intensity SPed gears at a depth of 127 microns and 540 pct. higher at a depth of 51 microns.

Townsend, Dennis P.↗

NASA NTRS1992

Gear tooth stress measurements of two helicopter planetary stages

Two versions of the planetary reduction stages from U.S. Army OH-58 helicopter main rotor transmissions were tested at NASA Lewis. One sequential and one nonsequential planetary were tested. Sun gear and ring gear teeth strains were measured, and stresses were calculated from the strains. The alternating stress at the fillet of both the loaded and unloaded sides of the teeth and at the root of the sun gear teeth are reported. Typical stress variations as the gear tooth moves through mesh are illustrated. At the tooth root location of the thin rimmed sun gear, a significant stress was produced by a phenomenon other than the passing of a planet gear. The load variation among the planets was studied. Each planet produced its own distinctive load distribution on the ring and sun gears. The load variation was less for a three planet, nonsequential design as compared to that of a four planet, sequential design. The reported results enhance the data base for gear stress levels and provide data for the validation of analytical methods.

Krantz, Timothy L.↗

NASA NTRS1994

Application of fault detection techniques to spiral bevel gear fatigue data

Results of applying a variety of gear fault detection techniques to experimental data is presented. A spiral bevel gear fatigue rig was used to initiate a naturally occurring fault and propagate the fault to a near catastrophic condition of the test gear pair. The spiral bevel gear fatigue test lasted a total of eighteen hours. At approximately five and a half hours into the test, the rig was stopped to inspect the gears for damage, at which time a small pit was identified on a tooth of the pinion. The test was then stopped an additional seven times throughout the rest of the test in order to observe and document the growth and propagation of the fault. The test was ended when a major portion of a pinion tooth broke off. A personal computer based diagnostic system was developed to obtain vibration data from the test rig, and to perform the on-line gear condition monitoring. A number of gear fault detection techniques, which use the signal average in both the time and frequency domain, were applied to the experimental data. Among the techniques investigated, two of the recently developed methods appeared to be the first to react to the start of tooth damage. These methods continued to react to the damage as the pitted area grew in size to cover approximately 75% of the face width of the pinion tooth. In addition, information gathered from one of the newer methods was found to be a good accumulative damage indicator. An unexpected result of the test showed that although the speed of the rig was held to within a band of six percent of the nominal speed, and the load within eighteen percent of nominal, the resulting speed and load variations substantially affected the performance of all of the gear fault detection techniques investigated.

Zakrajsek, James J.↗

NASA NTRS1994

Analysis of the Effects of Surface Pitting and Wear on the Vibrations of a Gear Transmission System

A comprehensive procedure to simulate and analyze the vibrations in a gear transmission system with surface pitting, 'wear' and partial tooth fracture of the gear teeth is presented. An analytical model was developed where the effects of surface pitting and wear of the gear tooth were simulated by phase and magnitude changes in the gear mesh stiffness. Changes in the gear mesh stiffness were incorporated into each gear-shaft model during the global dynamic simulation of the system. The overall dynamics of the system were evaluated by solving for the transient dynamics of each shaft system simultaneously with the vibration of the gearbox structure. In order to reduce the number of degrees-of-freedom in the system, a modal synthesis procedure was used in the global transient dynamic analysis of the overall transmission system. An FFT procedure was used to transform the averaged time signal into the frequency domain for signature analysis. In addition, the Wigner-Ville distribution was also introduced to examine the gear vibration in the joint time frequency domain for vibration pattern recognition. Experimental results obtained from a gear fatigue test rig at NASA Lewis Research Center were used to evaluate the analytical model.

Choy, F. K.↗

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 NTRS2001

Modeling, Modal Properties, and Mesh Stiffness Variation Instabilities of Planetary Gears

Planetary gear noise and vibration are primary concerns in their applications in helicopters, automobiles, aircraft engines, heavy machinery and marine vehicles. Dynamic analysis is essential to the noise and vibration reduction. This work analytically investigates some critical issues and advances the understanding of planetary gear dynamics. A lumped-parameter model is built for the dynamic analysis of general planetary gears. The unique properties of the natural frequency spectra and vibration modes are rigorously characterized. These special structures apply for general planetary gears with cyclic symmetry and, in practically important case, systems with diametrically opposed planets. The special vibration properties are useful for subsequent research. Taking advantage of the derived modal properties, the natural frequency and vibration mode sensitivities to design parameters are investigated. The key parameters include mesh stiffnesses, support/bearing stiffnesses, component masses, moments of inertia, and operating speed. The eigen-sensitivities are expressed in simple, closed-form formulae associated with modal strain and kinetic energies. As disorders (e.g., mesh stiffness variation. manufacturing and assembling errors) disturb the cyclic symmetry of planetary gears, their effects on the free vibration properties are quantitatively examined. Well-defined veering rules are derived to identify dramatic changes of natural frequencies and vibration modes under parameter variations. The knowledge of free vibration properties, eigen-sensitivities, and veering rules provide important information to effectively tune the natural frequencies and optimize structural design to minimize noise and vibration. Parametric instabilities excited by mesh stiffness variations are analytically studied for multi-mesh gear systems. The discrepancies of previous studies on parametric instability of two-stage gear chains are clarified using perturbation and numerical methods. The operating conditions causing parametric instabilities are expressed in closed-form suitable for design guidance. Using the well-defined modal properties of planetary gears, the effects of mesh parameters on parametric instability are analytically identified. Simple formulae are obtained to suppress particular instabilities by adjusting contact ratios and mesh phasing.

Parker, Robert G.↗

NASA NTRS2002

Torque Splitting by a Concentric Face Gear Transmission

Tests of a 167 Kilowatt (224 Horsepower) split torque face gearbox were performed by the Boeing Company in Mesa, Arizona, while working under a Defense Advanced Research Projects Agency (DARPA) Technology Reinvestment Program (TRP). This paper provides a summary of these cooperative tests, which were jointly funded by Boeing and DARPA. Design, manufacture and testing of the scaled-power TRP proof-of-concept (POC) split torque gearbox followed preliminary evaluations of the concept performed early in the program. The split torque tests were run using 200 N-m (1767 in-lbs) torque input to each side of the transmission. During tests, two input pinions were slow rolled while in mesh with the two face gears. Two idler gears were also used in the configuration to recombine torque near the output. Resistance was applied at the output face gear to create the required loading conditions in the gear teeth. A system of weights, pulleys and cables were used in the test rig to provide both the input and output loading. Strain gages applied in the tooth root fillets provided strain indication used to determine torque splitting conditions at the input pinions. The final two pinion-two idler tests indicated 52% to 48% average torque split capabilities for the two pinions. During the same tests, a 57% to 43% average distribution of the torque being recombined to the upper face gear from the lower face gear was measured between the two idlers. The POC split torque tests demonstrated that face gears can be applied effectively in split torque rotorcraft transmissions, yielding good potential for significant weight, cost and reliability improvements over existing equipment using spiral bevel gearing.

Filler, Robert R.↗

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.

Source record↗

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 NTRS2006

Failure of Harmonic Gears During Verification of a Two-Axis Gimbal for the Mars Reconnaissance Orbiter Spacecraft

The Mars Reconnaissance Orbiter (MRO) spacecraft has three two-axis gimbal assemblies that support and move the High Gain Antenna and two solar array wings. The gimbal assemblies are required to move almost continuously throughout the mission's seven-year lifetime, requiring a large number of output revolutions for each actuator in the gimbal assemblies. The actuator for each of the six axes consists of a two-phase brushless dc motor with a direct drive to the wave generator of a size-32 cup-type harmonic gear. During life testing of an actuator assembly, the harmonic gear teeth failed completely, leaving the size-32 harmonic gear with a maximum output torque capability less than 10% of its design capability. The investigation that followed the failure revealed limitations of the heritage material choices that were made for the harmonic gear components that had passed similar life requirements on several previous programs. Additionally, the methods used to increase the stiffness of a standard harmonic gear component set, while accepted practice for harmonic gears, is limited in its range. The stiffness of harmonic gear assemblies can be increased up to a maximum stiffness point that, if exceeded, compromises the reliability of the gear components for long life applications.

Johnson, Michael R.↗