AW Helicopter 360° Familiarization Course

Transmission Systems
Design and Development

Giuseppe Gasparini and Paul Newberry

Transmission and Mechanical Parts Center of Excellence

Yeovil, November 23rd, 2009

 TSD&D 360° Familiarization Course

Agenda

1. Introduction
2. Review of Helicopter Transmissions
3. General Design Criteria

4. Main Components
 Gears
 Bearing
 Housings

5. Other Components

6. TR Transmission
 IGB & TGB
 Shafts and Couplings

7. Vibration and Noise

8. Testing and Test Rigs
9. DMFG
 Introduction

FUNCTIONS CONSTRAINTS
• Minimum weight
• Transmit, Adjust (multiply or divide) • Maximum efficiency (> 0.96-0.98)
and Distribute torque and speed
• Minimum noise (emitted and/or
(power) from engines to rotors
transmitted)
• Transmit torque and speed (power) to
• Maximum fatigue life (> 10.000 h)
accessories
• Maximum TBO (> 5.000 h)
• Transmit the external loads from rotor
to structure • Minimum manufacturing cost
• Provide support to engines • Minimum cost of ownership
• Transmit the power required for level
flight after the oil loss for 30’
Introduction
Introduction
 Transmission Review

Agenda

1. Introduction
2. Review of Helicopter Transmission
3. General Criteria for Project
4. Main Components
 Gears
 Bearing
 Housings

5. Other Components
6. TR Transmission
 IGB & TGB
 Shafts and Couplings
7. Vibration and Noise
8. Testing and Test Rigs
9. DMFG
 Transmission Review – AW109/119

M/R Mast

Combining GearBox

Input Flange
Anti-Torque
beam Tail Rotor Take-off PT6 Engine Reduction GearBox
Transmissions Review – A129 EI/CBT

M/R Mast

Hydraulic
pump
MGB Input module
support
struts (8)

Lube oil
sump
 Transmissions Review – NH90

1st spiral M/R Mast

bevel stage
M/R Mast
RAGB
drive gears
Input module

4th epicyclic
stage

3rd helical
collector stage
2nd spiral
bevel stage

MGB drive train

Tail Rotor
Take-off
Servo-actuator
Accessory Module attachment
 Transmission Review – AW139/CMH

Input module for

M/R Mast accessory drive mode
(integrated hydraulic
& electric supply)
CMH MGB variant
(derived from
AW139 MGB)

Input module MGB drive train

M/R Mast

3rd
epicyclic
stage

Cooling
1st spiral
system bevel stage

Tail Rotor
Take-off 2nd spiral bevel
collector stage
 Transmissions Review – TRISYD / Nicetrip
Prop-rotor
Double-helical mast
ICDS input/ collector stage
output flange

ICDS
flange
Prop- Epicyclic
rotor Engine stage
mast input shaft
Double-helical
input stage

Input
flange

Prop-Rotor
GearBox (PRGB)
Transmission Review – VH-71B

M/R mast

M/R Tail Rotor

Mast Take-off
4th epicyclic
stage

2nd spiral
MGB1 bevel stage
cooling
system 3rd helical
stage

MGB2
cooling 1st spiral
system bevel stage
Oil filter
MGB drive train

Input
module
 Transmission Review – Lynx

Tail Rotor Gearbox

Main Rotor Gearbox

Intermediate Gearbox

Tail Drive Shafts

Transmission Review – Lynx (300)
M/R Mast
Cooling
system Collector stage

M/R Mast
Spiral bevel
input stage

“Load sharing”
“Torque split”
T/R Take-off

Input
flange

“Conformal” gears
on collector stage
 Transmission Review – Lynx (300)

Oil Cooling
System

MGB drive train

M/R Mast
M/R Mast

Collector
helical stage
Accessory cover
1st spiral
bevel stage

Input flange T/R Take-off

and Gimbal
 Transmission Review – AW159 (Future Lynx)

• List of major Modifications to the MGB:

• Output Shaft assembly changes.
– Change from Conformal to Involute
gears.
– Change from Titanium welded assembly
to a one piece Nitrided steel shaft.
– Revised Lift Bearing.
– Revised Lower Roller Bearing.
– New Lower Seal to replace existing
Stack Pipe.
– Top Cover and associated changes.
– Corrosion Improvements.
– Tail Take Off Housing.
Involute “Conformal”
– Fan Housing and impeller design
– Duplex Hardened Freewheel Cams.
– New Oil „OX125‟.
– Main-Drive Freewheel Actuator.
Transmission Review – AW159 (Future Lynx)

Future LYNX: Stage Collector Development

Transmission Review – AW159 (Future Lynx)
 Transmission Review – AW159 (Future Lynx)

SINGLE PIECE OUTPUT SHAFT - NEW ARRANGEMENT

• Single piece forging 32CDV13

• Nitriding instead of carburising
• Integral gear / hub / lower bearing
• Gears are shot peened &
superfinished
• Required to improve life
• Comparable strength / weight ratio
• Improved interface with rotor mast
and lift bearing
 Transmission Review – AW159 (Future Lynx)

Detailed FE Analysis of the gears

MGB casing and revised hub
created to understand internal
deflections and contact patterns
A good correlation between analysis
and test was achieved

PORT STBD AFT

 Transmission Review – AW159 (Future Lynx)

• List of major Modifications to the

TGB:
• Investment cast input housing in L168
• Machined from solid input housing
• Use existing TGB Donor output housing
• Oil Sensors
• Review actuator bearing design
• Improved attachment to tail structure
 Transmission Review – Various (UK)

• Other transmissions projects (UK)

• AW139 IGB, TGB and Tail drive shafts
• AW149 IGB & TGB
• AW129 IGB & TGB
• AW169 IGB & TGB
• Seaking and Apache support
 Transmission Review – T129 ATAK

M/R Mast Oil Cooling

System

MGB drive train

M/R Mast

4th epicyclic
stage
Support
struts (8)

Input
module 2nd spiral
bevel stage
3rd helical
Engine gimbal
collector
support stage
1st spiral Tail-Rotor
bevel stage Take-off
 Transmissions Review – AW149

M/R Mast

MGB drive train

Oil Cooling
System
M/R Mast

Input
3rd
module epicyclic
stage

1st spiral
bevel stage
Engine gimbal
support
2nd spiral bevel
collector stage
Transmissions Review – AWXX9

Tail Rotor
Gearbox

Main Gearbox

Intermediate Gearbox
 Transmission Review– Competitor 1

S76 EC Tiger

EC120 COMPETITORS
 Transmission Review – Competitor 2

COMPETITORS
Mi-17

S-92

B427/429
 General Design Criteria

Agenda

1. Introduction
2. Review of Helicopter Transmissions
3. General Design Criteria
4. Main Components
 Gears
 Bearings
 Housings

5. Other Components

6. TR Transmission
 IGB & TGB
 Shafts and Couplings

7. Vibration and Noise

8. Testing and Test Rigs
9. DMFG
General Design Criteria

Definitions of
DESIGN DATA
•Power
•Loads
•Requirements Choice of
•Rules ARCHITECTURE
•Dimentions
•Interfaces
•Competitors
Dimensioning of
GEARS
Dimensioning of Dimensioning of
SHAFTS BEARINGS

• Parts List (P/N) and Long-Lead-Item

Dimensioning of Dimensioning of • 3D Gears Scheme
LUBRICATION HOUSINGS • 3D Bearings Scheme
• Table tolerance and fits
• 3D nozzle and lubrication scheme
• Gear teeth, couplings and parameters of HT
• Bevel gear installation schemes
LAYOUT/STUDY of • Fasteners and standards part list
Transmission
• List and definitions of interfaces
• DMU of Oil Cooling System
• DMU of Transmission
End of
INTERATIONS
General Design Criteria

DRIVE SYSTEM POWER SPECTRA

1800
1600 Single Engine Input
1400 Twin Engine Input
POWER [KW]

1200 Main Rotor Output

1000 Tail Rotor Output

800
600
400
200
0
-200
0 10 20 30 40 50 60 70 80 90 100

CUMULATIVE OCCURRENCE [%]

1) For single engine load path use 2.5’ OEI
2) For twin engine load path use TOP reduced by
5% (accessory and TR)
3) For TR load path use 0.19-0.21 of TOP
General Design Criteria
 General Design Criteria

TOP TGB weight [Kg] PTOP (kW) WMGB = MGB weight [Kg]
W TGB 0.21 3.9 W MGB
10
TOP [kW]
5. 1 4 . 1 PTOP = TOP [kW]
Confronto pesi MGB
80
1200
EH101
70 4.1
1000 [kW/kg]
60
5.1
[kW/kg]
TGB Weight [kg]

NH90

MGB Mass [kg]

50 800

Massa MGB [kg]

6.0
AW139
[kW/kg]
40
600

30
A109
400
20 MGB
Competitors
200
10
MGB
A129 AgustaWestland
0 0
0 50 100 150 200 250 300 350 400 450 0 500 1000 1500 2000 2500 3000 3500 4000 4500

10% TOP [kW] Potenza massima al decollo [kW]

Maximum take off power
(TOP) [kW]
 Main Components

Agenda

1. Introduction
2. Review of Helicopter Transmissions
3. General Design Criteria

4. Main components
 Gears
 Bearings
 Housings

5. Other Components

6. TR Transmission
 IGB & TGB
 Shafts and Couplings

7. Vibration and Noise

8. Testing and Test Rigs
9. DMFG
Main Components

Spur Helical
gears Gear

Internal
Gears

Integral
inner
race

Flexible
web

Epicyclic stage
Main Components

3 gears on
the same
piece

Electron
Beam Welding
Main Components

Face
Gears

Double-Helical Gears
Main Components

K Factor
Wt mG 1
K
dP F mG

Segno (+) for external gears, (-) for internal gears

K K factor [psi]
Wt tangential load [lb]
dP pitch diameter [inch]
F tooth face width [inch]
mG transmissions ratio
(pinion teeth number / gear teeth number)

K Factor
K 1000 psi
Main Components

Bending strength verification

Pd K m K B
s t = Wt K o K v K s
F J

Pd diametral pitch[1/in]
F net face width of narrowest member [in]
J geometry factor
Ko overload factor
Kv dynamic factor
E

Ks size factor D

Km load distribution factor C

KB rim thickness factor B

A
Main Components

Pitting strength

K m Cf
s c = Cp Wt K o K v K s
dF I
Cp elastic coefficient= 2300
(E = 30 x 106 [psi]; = 0.30)
Wt transmitted tangential load [lb]
d reference diameter [inch]
F net face width of narrowest member [inch] E

I geometrical factor D

Ko overload factor C

Kv dynamic factor
B

Ks dimensional factor A

Km load distribution factor

Cf surface condition factor
Main Components

Scuffing strength
3 1
X w tr v tr
4 2
t fl 0.45 mXM XG 1
Cr 4

m mean coefficient of friction

XM heath factor - stretch
XG geometric factor
X load sharing factor
wtr transversal unit load
vtr operating speed
Cr distance between centre [inch]
t cMAX t M t flMAX
tcmax maximum contact temperature [ F]
tM “bulk” temperature [ F]
tflmax maximum "flash” temperature [ F]
Main Components

CARBURIZED STEEL:
• 9310 : nickel-chrome-molibdenum
- Highly stressed components of medium
- good weldability
• EX53: 9310 with other added elements
- temperature range of usage is much more extended
- most difficult to weld

NITRIDING STEEL:
• “ Nitralloy ” : nickel-chrome-molibdenum alluminium
• 32 CDV 13 : chrome-molibdenum-vanadium
• For components of medium large dimensions and/or more flexible
 Main Components

with external rings

3 points contact and double flange Duplex o Triplex

• Lower radial load capacity but good axial load capacity

• Significant sliding
• Close control of lubrication and cooling
• Can allow moderate misalineaments
Main Components

standard flanged with integral sleeve

• High radial load capacity but poor axial load capacity

• Sliding virtually absent, almost pure rolling
• Excellent efficiency: they require moderate lubrication
• Sensitive to misalignements
 Main Components

1) Angle of misalignement
increased ≈ 30’
2) Close control of
lubrication and cooling
3) Pay attentions to
material/treatment and
roughness of the inner
race

Single row of rollers Double row of rollers

Main Components

• High load capacity both axial and radial

Double row of rollers • Poor capacity to function without oil;
can therefore be used only on slow speed
shafts
• Pay attention to preload
• Poor tolerance to misalignements
Main Components

p
C 6
10
L 10
P 60 n

L10 unadjusted life [hours ]

C dynamic capacity of bearing calculated or from
catalogue [N]
P equivalent radial load acting on bearing [N]
n actual bearing rotation speed [rpm]
Other Components

Stress Analysis Design Pouring simulation Pattern Maker

Casting 2D

Machined 2D
 Other Components

Development methodology
Automatic
verification
thicknesses
CATIA V5 MODEL

GPS ANALYSIS

New Materials
Other Components
Foundry Equipment (Moulds, Core Boxes & Plaques)
Other Components
Core Box
Other Components
Sintered Cores
Other Components

FILLING SIMULATION (Temperature)

Other Components
Casting Process
 Other Components

Fettled Casting

Raw Casting
 Other Components

Each stage of gears: Nozzles Filter

Non-return
1 0.8 1.0% valvles
Cooler

Fan
Pumps
•3 stages 97 97.6 %
•4 stages 96 96.8 %

Q 0.0090 0.0110 PTOP

Q = oil flow [lit/min]
PTOP = take-off power [Hp]

1. Almost always “wet sump” scheme

2. Absence of pipes and external fittings
and connections Chip detector
“full flow”
 Other Components

Saldatura Listello-Calotta Thermostatic

valve
Calotta

Listello

Barrette

Filter housing
integral with
Saldatura Listello-Scambiatore heat exchanger

1) Type: cross counter flow heat exchanger

2) Directly connected to MGB casing to avoid
external pipes , fittings and hoses
3) Heat exchanger with ”drawing” fan
configuration
4) Attention to:
- Weldings
- Support
- Vibration
Other Components

Pressione

Rumore dB
Axial Portata 2kHz Freq

INLET

Centrifugal

Mixed Flow
DISCHARGE
1
1) Prevalent type: mixed flow
2) Attention to the impeller burst containment 2 n Q 2
k 3
3) Attention to vibration aspect: both produced and undergone 60 g h 4
4) Take into account the gyroscopic effects both on the stresses
and dynamics k = 1.5 (0.6 4.0)
4) Ceramic balls bearings with grease Mixed
5) Impeller aerodynamically optimized and machined from solid = 0.30 0.50
Flow
(not cast) = 0.10 0.25
Other Components

inlet

outlet

1) “GeRotor” (Generated ROTOR) type

2) Attention to tip speed (<12 m/s)
3) Attention must be paid to leakages due to
radial tip gap (< 0.01-0.02 mm)
Other Components

Pressure Regulating
Seals Jets Valves (PRV) Freewheel
 Other Components

Filter Actuators Chip Detectors

Torquemeter
 Trasmissione RC

Agenda

1. Introduction
2. Review of Helicopter Transmissions
3. General Design Criteria

4. Main Components
 Gears
 Bearings
 Housings

5. Other Components

6. TR Trasmission
 IGB & TGB
 Shafts and Couplings

7. Vibration and Noise

8. Testing and Test Rigs
9. DMFG
T/R Transmission

1. Low static and fatigue external

loads (lower if input and output
torques are balanced)
2. Attention to the installation to
facilitate alignment and
assembly/maintenance
3. Attention to cooling and lubrication
(study air-flow, exhaust engine flow,
finning on housing, fan)
 T/R Transmission

1. High static and fatigue

external loads (highest
if the tail rotor is not
teetering)
2. Attention to the
installation to
facilitate alignment,
assembly and
maintenance
3. Cooling and
lubrication not critical
(the air flow from tail
rotor helps)
4. Fasten the box to the
structure by bolts or
studs with bosses into
the casting
 T/R Transmission

Sub-Critical Shafts Super-Critical Shafts

nOP nCR1/1.30 1.45 nOP nCR1/0.45 0.65

N° shafts = 4 N° shafts = 2 (-2)

N° coupling = 5 N° coupling = 3 (-2)

N° support = 3 N° support = 1 (-2) (+2 damper )

1. The thickness of the tube has not effect on the

E I E s R3 E R2 critical speed
f k1 k2 k2 2. The ratio E/ change less for the steel ( 2650),
L4 A L4 R s L4
aluminium ( 2550) and titanium ( 2550)
T/R Transmission

1. Critical speed Buckling

2. Torsion Buckling
(elastic and/or elastic-plastic)

3. Static torsion

4. LCF (in particular EBW junctions

welded or riveted)

5. HCF junctions

6. Ballistic tolerance 5 9 5
1 R 4
s 4 3 Ey 8
M Crit 3
1
Ex8
7.5 1
L 2 xy yx
 T/R Transmission
CARBON FIBER
TAIL DRIVE SHAFT

E I E s R3 E R2
f k1 k2 k2
L A
4
L4 R s L4
TAIL DRIVE SHAFT BALLISTIC
TOLERANCE
E/ 4300 1.7 x All/Acc/Tit
Vcr increased approximately of 30%
T/R Transmission

fire tolerant shaft

dampers TGB

flexible couplings bearing supports IGB

(diaphragms type) pylon shaft
T/R Transmission

FROM MGB TO IGB

FOLDING CLOSED
T/R Transmission

Diaphragm type
 Link Engine / Transmission

Engine Side Gimbal

MGB Side Gimbal

MGB Input Module Engine Air Intake

Crosshead
Engine Side Gimbal

MGB Side Gimbal

MGB Input Module
 Vibration and Noise

Agenda

1. Introduction
2. Review of Helicopter Transmissions
3. General Design Criteria

4. Main Components
 Gears
 Bearings
 Housings

5. Other Components

6. TR Transmission
 IGB & TGB
 Shafts and Coupling

7. Vibration and noise

8. Testing and Test Rigs
9. DMFG
 Vibration and Noise

Dynamic Modeling
Identifications of the propagation
mechanisms of the vibro-acoustic Interior Noise
excitation and of modal
characteristics of the The analysis of the frequency
transmission members content of the acoustic traces
Peak-to- recorded inside the cabin
Peak identified the II stage gear set
Transmissio as a major noise source
n Error

Transmission
Error
Optimization
Reproduction of actual
meshing conditions as
the basis for the
optimization process
Vibration and Noise
COLLECTOR GEAR - ACCELEROMETRO A03

ORE PROVA ([Link]): 0.20 SEGNALE ENHANCED 02/08/02 16.50

50
PARAMETRI

40 M6 = 19,3

MFP = 1,1
30

Amplitude
PDV1 = 0,0004
20
PDV2 = 0,0000

10 C2 = 0,0000

Ampiezza (g)
MGB Accelerometers
0

-10

-20

-30

-40

-50
0 100 Samples
200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
CAMPIONI

COLLECTOR GEAR - ACCELEROMETRO A03

ORE PROVA ([Link]): 0.36 SEGNALE ENHANCED 06/08/02 10.39

50
PARAMETRI

40 M6 = 2883,6

MFP = 5,6
30

Amplitude
PDV1 = 0,0010
20
PDV2 = 0,0000

10 C2 = 0,0000

Ampiezza (g)
0

-10

-20

-30

-40

-50
0 100 Samples
200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
CAMPIONI

COLLECTOR GEAR - ACCELEROMETRO A03

ORE PROVA ([Link]): 0.45 SEGNALE ENHANCED 06/08/02 10.48

50
PARAMETRI

40 M6 = 3602,4

MFP = 7,2
30

Amplitude
PDV1 = 0,0016
20
PDV2 = 0,0000

10 C2 = 0,0000

Ampiezza (g)
0

-10

-20

-30

-40

Samples
-50
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
CAMPIONI

Fatigue damage nucleation could be detected before developing secondary failure

of significant dimensions and, in some cases, even before crack is entirely
propagated along the teeth
 Testing and Test Rigs

Agenda

1. Introduction
2. Review of Helicopter Transmissions
3. General Design Criteria

4. Main Components
 Gears
 Bears
 Housings

5. Other Components

6. TR Transmission
 IGB & TGB
 Shafts and Couplings

7. Vibration and Noise

8. Testing and Test Rigs
9. DMFG
Testing and Test Rigs

Transmission
Systems
Rotating Test
Rigs

Energy
Dissipating
Recovering

Mechanical Electrical Hydraulic

Testing and Test Rigs

Electrically Mechanically
Dissipative Rig
Regenerative Rig Regenerative Rig

0 0.75 0.85
Cost > Cost >> Cost <

Size > Size >> Size <<

Testing and Test Rigs
Testing and Test Rigs
Testing and Test Rigs

1. Minimum 30 minutes including

autorotation and flare
2. Critical elements: high-speed ball
bearing of the 1° stage
3. Possibly use emergency lubrication
devices
Testing and Test Rigs

Structural test (static and fatigue) on

single components
Endurance test on GTV, TDH, BSD
 Digital Manufacturing

Agenda

1. Introduction
2. Review of Helicopter Transmissions
3. General Design Criteria

4. Main Components
 Gears
 Bearings
 Housings

5. Other Components

6. TR Transmission
 IGB & TGB
 Shafts and Couplings

7. Vibration and Noise

8. Testing and Test Rigs
9. DMFG
Digital Manufacturing

Sheet Metal Cabling Composites

Machining Piping CMM Inspection

Digital Manufacturing

3D Digital Master
with Dimensions
and Tolerances
Conclusions