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TitleS&T Campaign: Sciences for Maneuver

Energy and PropulsionDistribution and Transfer

Mark Riggs, (410) 278-9604 mark.r.riggs.civ@mail.mil

Kelsen LaBerge, Ph.D., (216) 433-2078, kelsen.e.laberge.civ@mail.mil

Mark Valco, Ph.D., (216) 433-3717, mark.j.valco.civ@mail.mil

Brian Dykas, Ph.D., P.E. (410) 278-9545, brian.d.dykas.civ@mail.mil

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Less Metallic, Less Mechanical Drivetrains

Research ObjectiveAdvance the state-of-the-art in propulsion power transfer through novel propulsion power transfer components and concepts emphasizing reduced metallic content and fewer mechanical contacts, to include hybrid-electric propulsion, hybrid material systems for dynamic components, and magnetic gears

Challenges• Mechanical contacts within aerospace vehicle

transmissions are dependent on oil for cooling and lubrication which adds weight and poses a risk in the event the oil supply is interrupted

• Transmission noise accounts for the majority of cabin noise, particularly, in rotorcraft applications

• Transfer of shaft work at high torques in non-contacting transmissions

Parametric curve fit for rotary-wing aircraft gearbox and drive and lubrication system weight.+

ARL Facilities and Capabilities Available to Support Collaborative Research

• ARL facilities available at Aberdeen Proving Ground‒ Drives System Research Lab‒ Tribology laboratory‒ Bearing fatigue and loss-of-oil rigs

• Leveraged facilities at NASA Glenn Research Center‒ Gear test rigs (incl. spiral bevel, spur, face, and

helical)‒ Single gear tooth bending rigs‒ 500-hp helicopter transmission test rig‒ Variable speed aircraft transmission rig‒ Composite shaft test rig‒ Gear windage rig

• Software and modeling tools‒ Calyx (Advanced Numerical Solutions) finite element

code for gears, bearings and transmissions‒ Variable speed transmission modeling and

optimization codes‒ Gear windage modeling codes

Complementary Expertise/Facilities/ Capabilities Sought in Collaboration

• Expertise in aerospace vehicle transmissions• Expertise in high-power hybrid electrical propulsion

systems including: reliable electric machines with ultra high specific power, advanced power electronics, modeling and simulation, and controls

• Modeling and simulation for hybrid material propulsion components (including carbon fiber composites)

Examples of weight saving drive system technologies (hybrid composite gears and hybrid ceramic bearings)

+ M. T. Tong, S. M. Jones, W. J. Haller, and R. F. Handschuh, “Engine Conceptual Design Studies for a Hybrid Wing Body Aircraft,” NASA Glenn Research Center, Cleveland, OH, Technical Memorandum NASA/TM-2009-215680, Nov. 2009.

Desired future shift in drive system weight