AGMA-05FTM13-2005.pdf
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1、05FTM13 Evaluation of the Scuffing Resistance of Isotropic Superfinished Precision Gears by: P.W. Niskanen, Alion Science and Technology, B. Hansen, Sikorsky Aircraft Corporation and L. Winkelmann, REM Chemicals, Inc. TECHNICAL PAPER American Gear Manufacturers Association Copyright American Gear Ma
2、nufacturers Association Provided by IHS under license with AGMA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 11:58:03 MDTNo reproduction or networking permitted without license from IHS -,-,- Evaluation of the Scuffing Resistance of Isotropic Superfinished Precisio
3、n Gears Paul W. Niskanen, Alion Science and Technology, Bruce Hansen, Sikorsky Aircraft Corporation and Lane Winkelmann, REM Chemicals, Inc. The statements and opinions contained herein are those of the author and should not be construed as an official action or opinion of the American Gear Manufact
4、urers Association. Abstract The high performance required from aerospace gears places stringent requirements upon the metallurgical quality, geometry, and surface finish of mating parts. In an effort to meet their mission requirements, aerospace gears are often engineered to operate near the upper b
5、ounds of their theoretical design allowables. Due to this, scuffing is a primary failure mode for aerospace gears. It was previously shown that specimens having an isotropic superfinish using chemically accelerated vibratoryfinishinghadanimprovedperformanceinRolling/SlidingContactFatigue(R/SCF)testi
6、ng. Isotropic superfinishingimprovedR/SCFresistanceuptoninetimes thatofbaselinetestspecimens.These tests also demonstrated the ability to successfully carry 30 percent higher loads for at least three times the life of the baseline samples.1 A study was then conducted on actual gears having an isotro
7、pic superfinish.This study showed isotropic superfinishingtechnologyincreasedagearsresistancetocontactfatiguebyafactorofthree,andincreased bendingfatigueresistancebyatleast10percent.2 Thisincreaseingearperformancetranslatestoreduced operation and sustainment costs, and also offers the potential for
8、weight reduction in new transmission designs. The present paper will discuss an additional study which is underway to determine andcompare thescuffing resistance of isotropic superfinished aerospace gears to that of baseline ground gears. Sample gears were made from case carburized SAE 9310. These t
9、ests were conducted using a method that progressively increaseslubricanttemperatureuntilscuffingoccurs,ratherthanthetraditionalloadincreasingmethodused inFZGtestingrigs. TheresultsofthecurrenttestingrevealsthatisotropicsuperfinishedSAE9310specimens show at least a 40 F higher lubricant temperature a
10、t the point of scuffing compared to as-ground baseline gears. Based on these results and the previous studies, it was concluded that this isotropic superfinishing technology should be incorporated in all future aerospace gear designs. A later paper will report on similar scuffing testing performed o
11、n AMS 6308 gears due to run-outs achieved by both the baseline and isotropic superfinished samples during the current procedure. Copyright 2005 American Gear Manufacturers Association 500 Montgomery Street, Suite 350 Alexandria, Virginia, 22314 October, 2005 ISBN: 1-55589-861-0 Copyright American Ge
12、ar Manufacturers Association Provided by IHS under license with AGMA Licensee=IHS Employees/1111111001, User=Wing, Bernie Not for Resale, 04/18/2007 11:58:03 MDTNo reproduction or networking permitted without license from IHS -,-,- 1 Evaluation of the Scuffing Resistance of Isotropic Superfinished P
13、recision Gears Paul W. Niskanen, Alion Science and Technology Bruce Hansen, Sikorsky Aircraft Corporation and Lane Winkelmann, REM Chemicals, Inc. Introduction The high performance required from aerospace gears places stringent requirements upon the met- allurgical quality, geometry, and surface fin
14、ish of mating parts. In an effort to meet these require- ments, mating parts are often designed to operate near the upper bounds of their theoretical design strength envelope.Precision grinding after heat treatment is a standard practice used in the aero- space industryin orderto obtainthe necessary
15、final tolerancesdemandedbythe needto providehigher powerdensitylevels,withoutincreasingcomponent size or weight. Friction and wear between two sliding surfaces are in large part dependent upon the finish of the sur- face. Inparticular,theroughnessofthesurfacehas a strong influence on the coefficient
16、 of friction. Overcomingfriction,especiallyinhighperformance applications, involves stringent lubrication require- ments. Examples of applications requiring excep- tional surface finish include gears and bearings. A newsurfacefinishingtechnology,knownasIsotrop- ic Superfinish (ISF), has proven to be
17、 effective at reducinggearwear whileat thesame timereducing lubricationrequirements.Thisrevolutionary technology was developed for military helicopter applicationsaspartofboththeInstrumentedFacto- ry for Gears (INFAC) and Power Transfer Systems Manufacturing (PTSM) programs, sponsored by the US Army
18、 Aviation and Missile Command (AM- COM) at Redstone Arsenal.Initial testing per- formed by Alion Science and Technology Corpora- tion (formerly IIT Research Institute), under the Army MANTECH program (DAAJ09-95-C-0546), demonstratedthattheisotropic superfinishprocess improved performance in Rolling/
19、Sliding Contact Fatigue (R/SCF) specimens. This testing revealed that superfinished samples yielded improvements of up to 9 times thecontact fatiguelife ascompared to baseline test specimens. Isotropicsuperfinished specimens have also demonstrated the ability to successfully carry 30 percent higher
20、loads for at least3timesthelife ofthe baselinesamplesNO TAG. These promising INFAC results led to the compari- sontestingofactualaerospacequalitygearsinboth baseline (final ground) and isotropic superfinish conditions. This second project, conducted under the PTSM Program was titled, Engineered and
21、Su- perfinished Surfaces for Precision Aerospace Ap- plications (Manufacturing Technology Report, Oc- tober30,2002,ContractNo.DAAH23-00- C-R232). This project demonstrated the ability of isotropic superfinishing to increase a gears resist- ance to contact fatigue by a factor of 3, and to in- crease
22、bending fatigue resistance by at least 10 percent. This increase in gear performance trans- lates to reduced operation and sustainment costs and offers the potential for weight reduction in new transmission designs. However, the effect of the isotropic superfinish process on scuffing resistance of g
23、ears remained unknown. This lack of knowl- edge was an obstacle to implementation of the pro- cess. Consequently,itwasdeterminedthat dataon scuffing resistance must be obtained. Background The isotropic superfinish process is a commercially available process that when applied to helicopter transmiss
24、ion gears, can result in improved gear toothbendingandcontactfatigueresistanceaswell asreducednoise,vibration,andoperatingtempera- tures. 3 4 The isotropic superfinish process pro- videsauniformsurfacefinishbyreducingthepeaks on the surface through the use of chemically accel- erated vibratory finis
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