Experimental testing of prototype face gears for helicopter transmissions

An experimental program to test the feasibility of using face gears in a high-speed and high-power environment was conducted. Four face gear sets were tested, two sets at a time, in a closed-loop test stand at pinion rotational speeds to 19,100 rpm and to 271 kW. The test gear sets were one-half scale of the helicopter design gear set. Testing the gears at one-eighth power, the test gear set had slightly increased bending and compressive stresses when compared to the full scale design. The tests were performed in the LeRC spiral bevel gear test facility. All four sets of gears successfully ran at 100 percent of design torque and speed for 30 million pinion cycles, and two sets successfully ran at 200 percent of torque for an additional 30 million pinion cycles. The results, although limited, demonstrated the feasibility of using face gears for high-speed, high-load applications

Contact stress analysis of spiral bevel gears using nonlinear finite element static analysis

A procedure is presented for performing three-dimensional stress analysis of spiral bevel gears in mesh using the finite element method. The procedure involves generating a finite element model by solving equations that identify tooth surface coordinates. Coordinate transformations are used to orientate the gear and pinion for gear meshing. Contact boundary conditions are simulated with gap elements. A solution technique for correct orientation of the gap elements is given. Example models and results are presented

Showing their true colors: a practical approach to volume rendering from serial sections

<p>Abstract</p> <p>Background</p> <p>In comparison to more modern imaging methods, conventional light microscopy still offers a range of substantial advantages with regard to contrast options, accessible specimen size, and resolution. Currently, tomographic image data in particular is most commonly visualized in three dimensions using volume rendering. To date, this method has only very rarely been applied to image stacks taken from serial sections, whereas surface rendering is still the most prevalent method for presenting such data sets three-dimensionally. The aim of this study was to develop standard protocols for volume rendering of image stacks of serial sections, while retaining the benefits of light microscopy such as resolution and color information.</p> <p>Results</p> <p>Here we provide a set of protocols for acquiring high-resolution 3D images of diverse microscopic samples through volume rendering based on serial light microscopical sections using the 3D reconstruction software Amira (Visage Imaging Inc.). We overcome several technical obstacles and show that these renderings are comparable in quality and resolution to 3D visualizations using other methods. This practical approach for visualizing 3D micro-morphology in full color takes advantage of both the sub-micron resolution of light microscopy and the specificity of histological stains, by combining conventional histological sectioning techniques, digital image acquisition, three-dimensional image filtering, and 3D image manipulation and visualization technologies.</p> <p>Conclusions</p> <p>We show that this method can yield "true"-colored high-resolution 3D views of tissues as well as cellular and sub-cellular structures and thus represents a powerful tool for morphological, developmental, and comparative investigations. We conclude that the presented approach fills an important gap in the field of micro-anatomical 3D imaging and visualization methods by combining histological resolution and differentiation of details with 3D rendering of whole tissue samples. We demonstrate the method on selected invertebrate and vertebrate specimens, and propose that reinvestigation of historical serial section material may be regarded as a special benefit.</p

Phenomenological study of the behavior of some silica formers in a high velocity jet fuel burner

Samples of four silica formers: single crystal SiC, sintered alpha-SiC, reaction sintered Si3N4 and polycrystalline MoSi2, were subjected to a Mach 1 jet fuel burner for 1 hr, at a sample temperature of 1375 deg C (2500 deg F). Two phenomena were identified which may be deleterious to a gas turbine application of these materials. The glass layer formed on the MoSi2 deformed appreciably under the aerodynamic load. A scale developed on the samples of the other materials which consisted of particular matter from the gas stream entrapped in a SiO2 matrix

Comparison of Experimental and Analytical Tooth Bending Stress of Aerospace Spiral Bevel Gears

An experimental study to investigate the bending stress in aerospace-quality spiral bevel gears was performed. Tests were conducted in the NASA Lewis Spiral Bevel Gear Test Facility. Multiple teeth on the spiral bevel pinion were instrumented with strain gages and tests were conducted from static (slow roll) to 14400 RPM at power levels to 540kW (720 hp). Effects of changing speed and load on the bending stress were measured. Experimental results are compared to those found by three-dimensional finite element analysis

Gear Design Effects on the Performance of High Speed Helical Gear Trains as Used in Aerospace Drive Systems

The performance of high-speed helical gear trains is of particular importance for tiltrotor aircraft drive systems. These drive systems are used to provide speed reduction/torque multiplication from the gas turbine output shaft and provide the necessary offset between these parallel shafts in the aircraft. Four different design configurations have been tested in the NASA Glenn Research Center, High Speed Helical Gear Train Test Facility. The design configurations included the current aircraft design, current design with isotropic superfinished gear surfaces, double helical design (inward and outward pumping), increased pitch (finer teeth), and an increased helix angle. All designs were tested at multiple input shaft speeds (up to 15,000 rpm) and applied power (up to 5,000 hp). Also two lubrication, system-related, variables were tested: oil inlet temperature (160 to 250 F) and lubricating jet pressure (60 to 80 psig). Experimental data recorded from these tests included power loss of the helical system under study, the temperature increase of the lubricant from inlet to outlet of the drive system and fling off temperatures (radially and axially). Also, all gear systems were tested with and without shrouds around the gears. The empirical data resulting from this study will be useful to the design of future helical gear train systems anticipated for next generation rotorcraft drive systems

Results of NASA Technical Challenge to Demonstrate Two-Speed Drive for Vertical Lift Vehicle

Currently, manned vertical lift vehicles are flown in a manner such that the rotors operate over a narrow range of rotating speed regardless if the vehicle's flight condition is one of vertical takeoff and landing, hover, or forward cruise. The propulsion systems are optimized for operation at the same, corresponding narrow range of rotor speed. However, certain missions and markets benefit greatly if the rotor speed can be adjusted over a wide range of speed to match demands of different missions and flight regimes. A vehicle that can operate with a wide range of rotor speeds would address key barriers to enable new markets and missions for vertical lift vehicles. Key barriers addressed by the wide-range of rotor speed include noise reduced via lower rpm rotor, increase of maximum forward flight speed, increased payload and range, reduced fuel burn, and lower operating costs. A new paradigm for the propulsion system is needed to enable these key benefits. One viable approach is to make use of a two-speed ratio drive system such that the engine can continue to operate over a narrow speed range, whereby engine performance is optimal, while adjusting the rotor speed as needed using the two-speed drive system. Motivated by such needs and by results of several system studies, a NASA Revolutionary Vertical Lift Technology Challenge was established to develop and demonstrate required technologies and designs for achieving a 50% reduction in rotor rpm via a two-speed drive system that incurs less than 2% power loss and maintains current power-to-weight ratios. The technical challenge work was completed and the technical objectives were achieved. This report describes the motivations, the research approach and the significant outcomes

Contact Stress Analysis of Spiral Bevel Gears Using Finite Element Analysis

A procedure is presented for performing three-dimensional stress analysis of spiral bevel gears in mesh using the finite element method. The procedure involves generating a finite element model by solving equations that identify tooth surface coordinates. Coordinate transformations are used to orientate the gear and pinion for gear meshing. Contact boundary conditions are simulated with gap elements. A solution technique for correct orientation of the gap elements is given. Example models and results are presented

Comparison of Gap Elements and Contact Algorithm for 3D Contact Analysis of Spiral Bevel Gears

Three dimensional stress analysis of spiral bevel gears in mesh using the finite element method is presented. A finite element model is generated by solving equations that identify tooth surface coordinates. Contact is simulated by the automatic generation of nonpenetration constraints. This method is compared to a finite element contact analysis conducted with gap elements