ALBERT

Description: This work was motivated by a qualification test of a mechanism for a space telescope. During the test undesired wear debris was formed. In this project alterative materials and coatings were tested with intent to reduce wear and debris when steel has a misaligned rolling contact against Ti6Al4V. Testing was done using a vacuum roller rig mimicking the mechanism's contact conditions. Ten configurations were tested. Most configurations resulted in significant debris. A sputtered 1-micrometer-thick nan-ocomposite molybdenum disulfide (MoS2) film provided the best wear protection. The best configuration made use of the MoS2 coating on both materials, and in preparing for sputtering the anodized Ti6Al4V working surface was smoothed using an ultrasonic process.

Description: While the vibration analysis of gear systems has been developed, a systematic approach to the reduction of gearbox vibration has been lacking. The technique of reducing vibration by shifting natural frequencies is proposed here for gearboxes and other thin-plate structures using the theories of finite elements, modal analysis, and optimization. A triangular shell element with 18 degrees of freedom is developed for structural and dynamic analysis. To optimize, the overall vibration energy is adopted as the objective function to be minimized at the excitation frequency by varying the design variable (element thickness) under the constraint of overall constant weight. Modal analysis is used to determine the sensitivity of the vibration energy as a function of the eigenvalues and eigenvectors. The optimum design is found by the gradient projection method and a unidimensional search procedure. By applying the computer code to design problems for beams and plates, it was verified that the proposed method is effective in reducing vibration energy. The computer code is also applied to redesign the NASA Lewis gear noise rig test gearbox housing. As one example, only the shape of the top plate is varied, and the vibration energy levels of all the surfaces are reduced, yielding an overall reduction of 1/5 compared to the initial design. As a second example, the shapes of the top and two side plates are varied to yield an overall reduction in vibration energy of 1/30.

Description: Gears, bearings, and other mechanical elements transmit loads through contacting surfaces. Even if properly designed, manufactured, installed, and maintained, gears and bearings will eventually fail because of the fatigue of the working surfaces. Economical means for extending the fatigue lives of gears and bearings are highly desired, and coatings offer the opportunity to engineer surfaces to extend the fatigue lives of mechanical components. A tungsten-containing diamondlike-carbon coating exhibiting high hardness, low friction, and good toughness was evaluated for application to spur gears. Fatigue testing was done at the NASA Glenn Research Center on both uncoated and coated spur gears. The results showed that the coating extended the surface fatigue lives of the gears by a factor of about 5 relative to the uncoated gears. For the experiments, a lot of spur test gears made from AISI 9310 gear steel were case-carburized and ground to aerospace specifications. The geometries of the 28-tooth, 8-pitch gears were verified as meeting American Gear Manufacturing Association (AGMA) quality class 12. One-half of the gears were randomly selected for coating. The method of coating was selected to achieve desired adherence, toughness, hardness, and low-friction characteristics. First the gears to be coated were prepared by blasting (vapor honing) with Al2O3 particles and cleaning. Then, the gears were provided with a thin adhesion layer of elemental chromium followed by magnetron sputtering of the outer coating consisting of carbon (70 at.%), hydrogen (15 at.%), tungsten (12 at.%), and nickel (3 at.%) (atomic percent at the surface). In total, the coating thickness was about 2.5 to 3 microns. As compared with the steel substrate, the coated surface was harder by a factor of about 2 and had a smaller elastic modulus. All gears were tested using a 5-centistoke synthetic oil, a 10,000-rpm rotation speed, and a hertzian contact stress of at least 1.7 GPa (250 ksi). Tests were run until either surface fatigue occurred or 300 million stress cycles were completed. Tests were run using either a pair of uncoated gears or a pair of coated gears (coated gears mated with uncoated gears were not evaluated). The fatigue test results, shown on Weibull coordinates in the graph, demonstrate that the coating provided substantially longer fatigue lives even though some of the coated gears endured larger stresses. The increase in fatigue life was a factor of about 5 and the statistical confidence for the improvement is high (greater than 99 percent). Examination of the tested gears revealed substantial reductions of total wear for coated gears in comparison to uncoated gears. The coated gear surface topography changed with running, with localized areas of the tooth surface becoming smoother with running. Theories explaining how coatings can extend gear fatigue lives are research topics for coating, tribology, and fatigue specialists. This work was done as a partnership between NASA, the U.S. Army Research Laboratory, United Technologies Research Corporation, and Sikorsky Aircraft.

Description: The efficiency of a helicopter transmission planetary stage was studied both experimentally and analytically. Experiments were done by using a back-to-back, test-and-slave arrangement. The experiments were a parametric study of the effects of operating conditions on efficiency. In order to enhance the analysis, a model was developed that calculates the power required for the meshing gears to displace oil trapped between the gear teeth. In general, the analysis predicted higher efficiencies than were measured. The results of this study were compared with those of other studies.

Description: A study was conducted to compare the efficiency of two helicopter transmission planetary reduction stages. Experimental measurements and analytical predictions were made. The analysis predicted and experiments verified that one planetary stage was a more efficient design due to the type of planet bearing used in the stage. The effects of torque, speed, lubricant type, and lubricant temperature on planetary efficiency are discussed.

Description: Gears, bearings, and similar mechanical elements transmit loads through the surfaces that are in contact with one another. Thus, the fatigue lives of gears can be improved by providing smoother tooth surfaces. At the NASA Lewis Research Center, we completed a metrology evaluation of one method for making gears with a highly polished, mirrorlike surface. The polished gears were measured carefully. The measurement data showed that the polishing process did, indeed, reduce the surface roughness but did not change the overall tooth shape in any harmful way. This work was done as a partnership of NASA, the U.S. Army, and the University of Wales. NASA provided conventionally ground gear specimens and has begun testing to determine the fatigue lives of the superfinished gears. Under contract, the University of Wales superfinished the gears and inspected them before and after the superfinishing operation. The U.S. Army European Research Office provided the funds and procured the contract with the University of Wales.

Description: Split torque designs, proposed as alternatives to traditional planetary designs for helicopter main rotor transmissions, can save weight and be more reliable than traditional designs. This report presents the results of an analytical study of the system dynamics and performance of a split torque gearbox that uses a balance beam mechanism for load sharing. The Lagrange method was applied to develop a system of equations of motion. The mathematical model includes time-varying gear mesh stiffness, friction, and manufacturing errors. Cornell's method for calculating the stiffness of spur gear teeth was extended and applied to helical gears. The phenomenon of sidebands spaced at shaft frequencies about gear mesh fundamental frequencies was simulated by modeling total composite gear errors as sinusoid functions. Although the gearbox has symmetric geometry, the loads and motions of the two power paths differ. Friction must be considered to properly evaluate the balance beam mechanism. For the design studied, the balance beam is not an effective device for load sharing unless the coefficient of friction is less than 0.003. The complete system stiffness as represented by the stiffness matrix used in this analysis must be considered to precisely determine the optimal tooth indexing position.

Description: A collection of significant accomplishments from the research of the Mechanical Systems Technology Branch at the NASA Lewis Research Center completed during the years 1985-1992 is included. The publication highlights and accomplishments made in bearing and gearing technology through in-house research, university grants, and industry contracted projects. The publication also includes a complete listing of branch publications for these years.

Description: As part of NASA s Return-To-Flight efforts, the Space Operations Program investigated the condition of actuators for the orbiter s rudder speed brake. The actuators control the position of the rudder panels located in the tail of the orbiter, providing both steering control and braking during reentry, approach, and landing. Inspections of flight hardware revealed fretting and wear damage to the critical working surfaces of the actuator gears. To best understand the root cause of the observed damage and to help establish an appropriate reuse and maintenance plan for these safety critical parts, researchers completed a set of gear wear experiments at the NASA Glenn Research Center.

Description: Split path gearboxes can be attractive alternatives to the common planetary designs for rotorcraft, but because they have seen little use, they are relatively high risk designs. To help reduce the risk of fielding a rotorcraft with a split path gearbox, the vibration and dynamic characteristics of such a gearbox were studied. A mathematical model was developed by using the Lagrangian method, and it was applied to study the effect of three design variables on the natural frequencies and vibration energy of the gearbox. The first design variable, shaft angle, had little influence on the natural frequencies. The second variable, mesh phasing, had a strong effect on the levels of vibration energy, with phase angles of 0 deg and 180 deg producing low vibration levels. The third design variable, the stiffness of the shafts connecting the spur gears to the helical pinions, strongly influenced the natural frequencies of some of the vibration modes, including two of the dominant modes. We found that, to achieve the lowest level of vibration energy, the natural frequencies of these two dominant modes should be less than those of the main excitation sources.