Computational Design and Optimization of Non-Circular Gears

We study a general form of gears known as non‐circular gears that can transfer periodic motion with variable speed through their irregular shapes and eccentric rotation centers. To design functional non‐circular gears is nontrivial, since the gear pair must have compatible shape to keep in contact during motion, so the driver gear can push the follower to rotate via a bounded torque that the motor can exert. To address the challenge, we model the geometry, kinematics, and dynamics of non‐circular gears, formulate the design problem as a shape optimization, and identify necessary independent variables in the optimization search. Taking a pair of 2D shapes as inputs, our method optimizes them into gears by locating the rotation center on each shape, minimally modifying each shape to form the gear's boundary, and constructing appropriate teeth for gear meshing. Our optimized gears not only resemble the inputs but can also drive the motion with relatively small torque. We demonstrate our method's usability by generating a rich variety of non‐circular gears from various inputs and 3D printing several of the

Development of a novel gerotor pump for lubrication systems of aeronautic engines

The technology of lubrication systems for aircrafts engines has seen significant development during the history of aeronautics and has progressed in parallel with the evolution of the engines themselves. Starting from the first, wetsump schemes derived from automotive applications, more complex systems and components have been introduced. The progressive increase of aeronautic engines’ power and speed, as well as that of the maximum operative altitude of the aircraft, have increased the lubricant flow rate required to avoid severe mechanical issues that can cause dangerous conditions for the vehicle and its users. Currently, the main focus on the development of novel lubrication pumps is aimed at reducing the pumps’ weight and envelope while maintaining, or possibly increasing, their reliability. The first two objective could be pursued by searching for novel pump types and/or increasing the pump speed in order to downsize its required capacity, but the low-pressure environment, typical of the lubrication circuits, over imposes a few, severe, limitations to avoid cavitation occurrence that decrease the effectiveness of this approach. The central aim of the presented research, performed within the program “Greening the Propulsion”, is to provide a theoretical framework to help in the development of a novel gerotor pump for the lubrication of aeronautic engines.The first step of the research involves the study of the state of the art of aeronautic engines’ lubrication systems, providing particular care to the effect that any design choice and possible operational condition may have on the lubrication pump design. Hence, the state of the art for gerotor pumps is investigated; results of this study are used, along with catalogue comparisons, to build simplified sizing tools to perform a benchmarking activity involving gerotors and other low pressure pumps type. This activity, performed to position gerotor pumps in the aeronautic engine lubrication market, is then used as a starting point to highlight the weak points of gerotors traditional design and to propose some possible solutions to enhance the pumps performances. To study the outcomes of these modifications, a rigorous theoretical framework is required; sizing and modeling criteria, based on the theory of gearing and compressible fluids, are hence detailed and used to build an Automatic Design and Simulation Framework, able to automatically design, validate and simulate a novel gerotor pump given a minimum number of geometrical and physical input parameters. This design and simulation tool is then used to evaluate the performance boost provided by the proposed variations and to optimize the gears profiles by pairing it with a multiobjective algorithm based on evolutionary strategies. Another critical component of any lubrication system is the pressure relief valve used to avoid the occurrence of dangerous conditions for the pipes integrity. A side activity involving the study of a preliminary sizing tool for pressure relief valve is hence performed. A preliminary design framework is presented and discussed, highlighting the importance of the valve discharge coefficient. To study its dependence on the valve’s geometry, a lengthy CFD simulation campaign is performed varying the poppet shape and the fluid Reynolds’ number. Results are hence discussed and used inside the design framework

A review of gerotor technology in hydraulic machines

Over the years, numerous investigations have established the gerotor fundamentals. This work aims to provide a complete review of the literature from the last decade, focusing on the articles published in the past five years on gerotor technology in hydraulic machines. The report gives a catalogue of guidelines based on the trochoidal-envelope definition, a background analysis, the worldwide distribution of articles in each continent and country and the most frequently used keywords in the field. The paper identifies state-of-the-art research, and reports on current mainstream ideas. From the historical background, this literature review reports the current approaches in gerotor pumps (geometry and performance approaches, modeling and numerical simulations), orbital motors and new concepts. The report will serve as a guide and a directory for novel engineers working with gerotor technology in hydraulic machines. Another intention of this paper is to disseminate the works of the researchers who use this technology around the world, and to provide a scenario for future international collaboration. The paper gives an account of the disparity between academia and engineering applications. There is currently very little published literature on design and production methodologies for gerotor pumps and orbital motors. Hence, the future goal is to collect recommendations that combine academia and industry expertise to make better use of these extensive studies in the fieldPostprint (published version

Models for Flow Rate Simulation in Gear Pumps: A Review

Gear pumps represent the majority of the fixed displacement machines used for flow generation in fluid power systems. In this context, the paper presents a review of the different methodologies used in the last years for the simulation of the flow rates generated by gerotor, external gear and crescent pumps. As far as the lumped parameter models are concerned, different ways of selecting the control volumes into which the pump is split are analyzed and the main governing equations are presented. The principles and the applications of distributed models from 1D to 3D are reported. A specific section is dedicated to the methods for the evaluation of the necessary geometric quantities: analytic, numerical and Computer-Aided Design (CAD)-based. The more recent studies taking into account the influence on leakages of the interactions between the fluid and the mechanical parts are explained. Finally the models for the simulation of the fluid aeration are described. The review brings to evidence the increasing effort for improving the simulation models used for the design and the optimization of the gear machines

Models for Flow Rate Simulation in Gear Pumps: A Review

Gear pumps represent the majority of the fixed displacement machines used for flow generation in fluid power systems. In this context, the paper presents a review of the different methodologies used in the last years for the simulation of the flow rates generated by gerotor, external gear and crescent pumps. As far as the lumped parameter models are concerned, different ways of selecting the control volumes into which the pump is split are analyzed and the main governing equations are presented. The principles and the applications of distributed models from 1D to 3D are reported. A specific section is dedicated to the methods for the evaluation of the necessary geometric quantities: analytic, numerical and Computer-Aided Design (CAD)-based. The more recent studies taking into account the influence on leakages of the interactions between the fluid and the mechanical parts are explained. Finally the models for the simulation of the fluid aeration are described. The review brings to evidence the increasing effort for improving the simulation models used for the design and the optimization of the gear machines

Structural dynamics branch research and accomplishments to FY 1992

This publication contains a collection of fiscal year 1992 research highlights from the Structural Dynamics Branch at NASA LeRC. Highlights from the branch's major work areas--Aeroelasticity, Vibration Control, Dynamic Systems, and Computational Structural Methods are included in the report as well as a listing of the fiscal year 1992 branch publications

Crafting chaos: computational design of contraptions with complex behaviour

The 2010s saw the democratisation of digital fabrication technologies. Although this phenomenon made fabrication more accessible, physical assemblies displaying a complex behaviour are still difficult to design. While many methods support the creation of complex shapes and assemblies, managing a complex behaviour is often assumed to be a tedious aspect of the design process. As a result, the complex parts of the behaviour are either deemed negligible (when possible) or managed directly by the software, without offering much fine-grained user control. This thesis argues that efficient methods can support designers seeking complex behaviours by increasing their level of control over these behaviours. To demonstrate this, I study two types of artistic devices that are particularly challenging to design: drawing machines, and chain reaction contraptions. These artefacts’ complex behaviour can change dramatically even as their components are moved by a small amount. The first case study aims to facilitate the exploration and progressive refinement of complex patterns generated by drawing machines under drawing-level user-defined constraints. The approach was evaluated with a user study, and several machines drawing the expected pattern were fabricated. In the second case study, I propose an algorithm to optimise the layout of complex chain reaction contraptions described by a causal graph of events in order to make them robust to uncertainty. Several machines optimised with this method were successfully assembled and run. This thesis makes the following contributions: (1) support complex behaviour specifications; (2) enable users to easily explore design variations that respect these specifications; and (3) optimise the layout of a physical assembly to maximise the probability of real-life success

Combined misalignments in spur gear transmission systems: a semi-empirical approach

Un área inexplorada en el diseño de sistemas de transmisión de engranajes es el estudio de los efectos de desalineamientos combinados en las medidas de vibración. Actualmente, las investigaciones se centran en desalineamientos individuales y no combinados los cuales reflejan mejor los escenarios de aplicaciones reales. En esta investigación se analizan los efectos de los desalineamientos combinados en las mediciones de vibración en la base de los rodamientos y en el esfuerzo de flexión de los dientes de engranajes rectos de un sistema de transmisión de una etapa. Se diseñó y construyó un banco de pruebas para generar desalineamientos radiales, axiales y angulares en un sistema de transmisión de engranajes de una etapa. Se evaluaron todas las combinaciones posibles de niveles extremos de desalineamiento para un par de engranajes rectos para identificar tendencias en la respuesta vibratoria. Se desarrolló un modelo teórico del área de contacto proyectada para estudiar la relación entre esta y la respuesta vibratoria. Al analizar el cambio en los espectros, se determinó la influencia de diferentes desalineamientos y sus interacciones en las mediciones de vibración. Finalmente, se desarrolló un modelo híbrido para estimar las aceleraciones en los rodamientos, utilizando un modelo de elementos finitos para determinar el esfuerzo de flexión en los dientes y un modelo analítico para estimar las señales de vibración en los rodamientos. El modelo demostró una alta correlación en comparación con los resultados experimentales, validando su efectividad. Finalmente, se propusieron recomendaciones de diseño considerando las zonas de esfuerzo y vibración de interés.DoctoradoDoctor en Ingeniería Mecánic

Fatigue-Induced Failure in Horizontal-Axis Wind-Turbine (HAWT) Blades and HAWT Drivetrain Gears

Wind energy is one of the most promising and the fastest growing installed alternative-energy production technologies. In fact, it is anticipated that by 2030, at least 20% of the U.S. energy needs will be met by various onshore and offshore wind-farms [a collection of wind-turbines (converters of wind energy into electrical energy) at the same location]. A majority of wind turbines nowadays fall into the class of the so-called Horizontal Axis Wind Turbines (HAWTs). Turbine blades and the gearbox are perhaps the most critical components/subsystems in the present designs of HAWTs. The combination of high failure rates (particularly those associated with turbine-blades and gear-boxes), long downtimes and the high cost of repair remains one of the major problems to the wind-energy industry today. In the case of HAWT blades, one is typically concerned about the following two quasi-static structural-performance requirements: (a) sufficient \u27flap-wise\u27 bending strength to withstand highly-rare extreme static-loading conditions (e.g., 50-year return-period gust, a short strong blast of wind); and (b) sufficient turbine blade \u27flap-wise\u27 bending stiffness in order to ensure that a minimal clearance is maintained between blade tip and the turbine tower at all times during wind turbine operation. If these two structural requirements are not met, HAWT blades typically fail prematurely. In addition to the aforementioned quasi-static structural-performance requirements, one is also concerned about the premature-failure caused by inadequate fatigue-based durability of the HAWT blades. The durability requirement for the turbine blades is typically defined as a minimum of 20-year fatigue life (which corresponds roughly to ca. 108 cycles) when subjected to stochastic wind-loading conditions and cyclic gravity-induced edge-wise bending loads in the presence of thermally-fluctuating and environmentally challenging conditions. In the present work, a computational framework has been developed to address: (a) structural response of HAWT blades subjected to extreme loading conditions; (b) high-cycle-fatigue-controlled durability of the HAWT blades; and (c) methodology for HAWT-blade material selection. To validate the computational approach used, key results are compared with their experimental counterparts available in the public-domain literature. As far as the HAWT gear-boxes are concerned, while they are designed for the entire life (ca. 20 years) of the HAWT, in practice, most gear-boxes have to be repaired or even overhauled considerably earlier (3-5 years). Typically, a HAWT gear-box fails either due to the bending-fatigue-induced failure of its gears, or by tribo-chemical degradation and failure of its bearings. In the present work, a computational framework has been developed to predict HAWT service-life under extreme loading and unfavorable kinematic conditions, for the case when the gear-box service-life is controlled by gear-tooth bending-fatigue failure. In addition, a preliminary investigation of gear-box bearing kinematics, which can result in undesirable rolling-element skidding conditions, is conducted