Tribology & Mechanical Components Branch Overview Dr. Robert F ...
Transcript of Tribology & Mechanical Components Branch Overview Dr. Robert F ...
Tribology & Mechanical ComponentsBranch Overview
Dr. Robert F. Handschuh
NASA Glenn Research Center
Cleveland, Ohio, U.S.A.
Abstract:
An overview of NASA Glenn Research Center's Tribology & MechanicalComponents Branch is provided. Work in space mechanisms, seals,oil-free turbomachinery, and mechanical components is presented.An overview of current research for these technology areas iscontained in this overview.
https://ntrs.nasa.gov/search.jsp?R=20100041305 2018-02-01T03:39:09+00:00Z
Tribology &Mechanical ComponentsBranch Overview
Dr. Robert F. HandschuhNASA Glenn Research Center
Cleveland, Ohio, U.S.A.
Topics
• View from 30,000 feet• Structures and Materials Division• Tribology &Mechanical Components Branch• Branch teams• Oil-free bearing research activities• Tribology activities• Seals Team activities• Drive system activities• Summary
NASA Glenn Research Center
AeroshellsTPS; Cooled strs.Cryogenic tanksNacellesCombustorsEngine fan systemMechanismsOil-Free enginesInjectorsHigh-power motorsSpace lubricantsProtective CoatingsSensorsThermoelectrics
Surface mobility systemsNozzlesIn-space & on-surface modulesRotor discs and systemsTurbine vanesEnergy absorbing systemsMechanical drive systemsHuman health systemsThrustersBearings and flywheelsSolid oxide fuel cells, batteriesHigh temp. and cryogenic sealsPorous membranesBN nanotubes
ore R&T Capabilities
Materials and Structures Division CapabilitiMateria ls and Structures Division
Propulsion and Power System Components
Probabilistic methodsMechanical power transferImpact dynamicsStructural mechanicsMaterial modelingMaterial characterizationFunctional materialsMetallic alloysComputational materialsSurface scienceMaterials science
Matl. and strl. ConceptsHealth prognosticsBlast mechanicsStructural dynamicsJoining technologyFailure and damage growthProcessing technologiesShape memory alloysProtective coatingsExtreme environment effectsHigh temperature chemistry
Design technologyExperimental methodsMeasurement technologyAeroelasticityDurability and lifeFatigue and fractureHigh temp. and cryo sealsCeramic materialsMultifunctional MaterialsLubricant chemistryFriction and wear
rTribology & Mechanical Components Branch
“NASA ʼs one-stop-shop for all itsmechanisms & lubrication needs”
Branch Organization:
â Oil-Free Turbomachinery – Dr. Chris DellaCorte
â Space Mechanisms & Lubrication – Dr. Phil Abel
â Aerospace Seals – Dr. Bruce Steinetz
â Aero Drive Systems – Dr. Robert Handschuh
Heat Shield
Interface Seal
Docking Seal
• Space habitat seals for extreme environments• Structural / thermal protection seals• Non-contacting turbine seals
• Gear fatigue research• High speed gear lubrication• Drive system diagnostics• Fatigue crack modeling• Dynamic mechanical components• Rotorcraft transmission systems• Advanced rolling element andwave bearing technologies
• Tribology & Mechanical Components Branch
Oil-Free Turbomachinery
Space Mechanisms & Lubrication
From basicresearch to
ppa lication
• Aero / Space application• World-leading bearing experts• Advanced modeling methods• Foil bearing predictive design
Aerospace Seals Research
• Accelerated space lubricant life testing under vacuum• New mechanism concepts for planetary environment• New space lubricant development• Terramechanics modeling & testing for efficient wheels
Aero Drive Systems
TGIR Award for Level I Milestone:“Core Hot Bearing Tests” (OFTET)
Foil air bearingsCAD
Oil-Free Turbomachinery
Oil-Free enabling technologies ?
r
PM304 bushings forindustrial furnaces
and valves
P10", Oil-Free Key Facilities & Capabilities
ambient pressure test rig
Coating depositionresearch facility
MicroTurbineproof-of-concept& environmental
durability testfacility
Hot high-speedShaft rotordynamicthrust foil bearing rigsimulator test facility
Space Tribology & Materials
BEARING RIGFull Scale
Bearing Tests
SPIRAL ORBIT TRIBOMETERAccelerated Lubricant Life
Testing Under RealisticConditions
VACUUM 4-BALLAccelerated Bulk Property
Testing of Lubricants .
Other Facilities:*Vapor Pressure of Fluids*Radiation Damage of
Polymers
Heating soot to hightemperatures in aninert atmosphere
graphitizes thecarbon
to form nano-onions.
Nano-Structured Lubricants for Tribology
Carbon nanostructure transformation by industriallyscalable GRC developed process
Addition of a small amount of nano-onions to oil improved the lifetime by a factor of 8x while decreasing the friction by a factor of 2.6
Spiral Orbit Tribometer (SOT) SOT Nano-grease Friction TracesRotating plate 1000 moo 3000 moo(tilted up for clarity) - I Rotation u 3
Ball orbit -^ '^Spiral orbit Nano-onions mixed with oil ox®
: ^ (I^'yt
143AB) form a nano-grease. Whentested in the SOT, which mimics themotion of a ball bearing, significantfriction and lifetime improvements o.
in air are realized.
of
Orbits
Surface Science Tools
Raman
Dft„ema.ek-91- --p-dto aiff—t c Chermam b—fi w
.m.s.e rwtn mir.na my ccz aawRedNbnP^MYn.gWan: CF3 V.G.
. w^.C.F^ 0 FT-IR
Depth (,,Metres)
Auger
0 1 2 3,um
AFM
Thermal barrier for Shuttle andAtlas V SRM nozzle joints
NASA GRC Seal Team
NASA GRC Seal Team contributions haveinfluenced several flight projects:
- Shuttle main landing gear door environmental seals- Thermal barrier (braided carbon fiber rope) for
nozzle joints of Shuttle and Atlas V SRM’s
ShelMechanical seal attac
Shelf/sealing surface:AETB-8 ,tile ;on'aluminstructure
NASA GRC Seal Team Overview
• NASA GRC Seal Team contributions have influencedseveral flight projects:– X-38 rudder/fin seals– X-37 flaperon seals
Low Impact Docking System (LIDS)
• LIDS is a system under developmentby NASA JSC designed to:
– Provide gender-neutral(androgynous) interface permittingdocking and berthing between anytwo space vehicles
– Reduce impact loads between twomating space craft
– Become new Agency standard fordocking/berthing systems
alignment
Seal Test Facilities
Spiral Bevel / Face Gear Test Facilities Gear Noise / Dynamics Test Facility
Drive System Test Facilities
Spur Gear Fatigue Test Rigs
Split Torque Test Facility
OH-58 Transmission Test Facility
High Speed Helical Gear Train Facility
Drive System Analytical Capabilities
Finite Element BasedStructural - Thermal
Planetary Gear Dynamics
99
98
97
EfÞciency(%)
96
95
94
1000
/ 0 Experimental Results 12500 RPMd —,0— Experimental Results 15000 RPM
• •^^• Analytical Prediction 12500 RPM• • y* • Analytical Prediction 15000 RPM
2000 3000 4000 5000
Gearbox Power (hp)
High Speed Gearing ResultsNASA - ARL/VTD - Bell Helicopter
100 -
_ ___ = -'" Bearing Losses80
Total` _...._.._.....
Losses 60 Gear Meshing Losses
(hp)
40
WIndage Losses20
08000 10000 12000 14000 16000 18000 20000
Input Torque (in*lb)
P Windage = C3 C ' N 2.85D4.7v 0.15
70
------------ - f Dawson Model 1% Lube-60 ----------------- —v— Dawson Model 0.75% Lube -------- --- -
• ---f Daswson Model Lube •:--_-_-_ - ------_-- •• -•••_-_-_-_-_-_-_
- • %% Dawson Model 0.25% Lube
• -50 • • • --- ,------ • —^ Dawson Model - No Lube '------ . "'""
Windage .........::-- --,..........._......::::::::::: .... .....'Power 40-..
- ---, .. ............. :... ........- ,Loss -
- --- --------(hp) 30 ........... .. ... ......... _ ................... . .....,- - ,..
-------- ---- -------tom:........ ---- --
20
10 _ ^.....- —--------------...... .. k - -
06000 8000 10000 12000 14000
Input Shaft Speed (RPM)
Condition Based Maintenance
Objectives: Increase reliability and decrease false alarms formechanical component diagnostics. Demonstrate integration of oildebris and vibration based damage detection techniques results inimproved capability.
Approach:Instrument and monitor all GRC gear fatigue test facilities and workwith other govt. agencies, university, and industry
Condition Based Maintenance
Vibration Techniques
151 ^^15 (FM4,NA4) and Oil
,j Debris
^q 10 7 f J^ 11 S 10^
RW
f i,
r +r r °
r.-- n • ^ ^ n ^
^ 500 100D 1500 2000 2500 3000 3.50 1
Reading Number 1 - r
0.9 DamageCLa 0.8
0.7
0.6
7@- 0.5 Inspect0.4
Output of 0.3
0.2
Fuzzy Logic Model 0. 1-, Normal0
0 500 1000 1500 2000 2500 3000 3500
Reading Number
Test Facility
Wave Bearing Technology
Bearing Concept
• Improved stability and cooling• Ability to tailor stiffness and damping• Use of hard sleeves
Fracture Toughness
Ferrium C69 AISI 9310
Surface Fatigue Results
Gear Number Number of Median lifeMaterial of tests (million
failures completed cycles)
AMS 15 21 1346308B[Ref. 10]
AISI 25 33 2009310[Ref. 13]
Ferrium 5 10 361® C69[presentstudy]
Advanced Gear Material
b, e^07 o4y1' r r,' • Excellent Contact Fatigue• Poor Fracture Toughness
Space Mechanism Wear
Dither Damage Assessment
650
600
550
500
450
400
350
300
250
200
Bending
Stress
Index
(ksi)
Low Cycle Bending Fatigue
1e+0 1e+1 1e+2 1e+3 1e+4 1e+5
Cycles
Tilt Axis Combiner GearboxGearbox
ReductionGearbox
rCivil Tiltrotor Drive System Configuration
To Mid-WingGearbox Variable /Multi-Speed
n Gearbox
Hover Ratio 131.4: 1 Forward Flight Ratio 243.6 : 1
GearPerformance
Penn State Univ. - NASA NRA R&D
RotorcraftConfiguration —^ Assemble Model
Flight r—— ——^Condition .
I IPilot Flight Control System
Inputs System Model .
I II I
Powertrain •
Control Law
I I
SystemDynamics
Subsonic Rotary Wing: High FidelityDesign Tools
Windage Test Facility, NASA-GRC
Drive Motor
Speed Increasing'- Gearbox -
Dr. Robert F. Handschuh, Army Research Lab, NASA - GlennMark A. Stevens, NASA Glenn Research Center
Input Output
In-Line Two Speed Advanced RC Drive Systemr
J Wet / Dry Clutch
Over-Running Clutch
High Speed Operation (hover): Wet/ Dry Clutch engaged, Over-Running Clutch over-runningLow Speed Operation (cruise): Wet/ Dry Clutch disengaged, Over-Running Clutch driving
Dr. Robert F. Handschuh (October 2007)
Flywheel
DriveMotor
Flywheel
TorsionalLoad
Variable / Multi-Speed Drive FacilityConcept
TransmissionConcept
Summary
• Four main focus areas in the drive system area:* Oil-Free Turbomachinery* Tribology –Surface Science* Seals –Static and Dynamic* Drive System Technologies
• Currently conduct /manage research within ourcenter as well as at contractor and university locations
• Involved in analytical and experimentaldevelopments
• Work closely with the space &aerospace industry,other government agencies / NASA centers, NESCÉ.