SBIR-STTR Award

The proposed program will focus on the development of a new generation of advanced technology for rotorcraft transmission systems. This program will evaluate the viability of integrating gears with composite shafts. The aim of this work is to reduce overall weight and improve vibration characteristics. Two concepts have been identified and will be further researched. The first design includes co-molding a bearing race to a carbon fiber reinforced composite shaft. The second design integrates the composite shaft and metallic gear in a way that allows shaft misalignment in the power transmission system. These attachments will simplify gear attachment and have the potential to reduce weight by integrating parts without the need for secondary fasteners. This development work will allow for widespread application in both military and civil rotorcraft systems.

Potential NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) Successful results of this program will lead to widespread application in all military and civilian rotorcraft transmission systems.

Potential NON-NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) Successful results of this program will lead to widespread application in all military and civilian rotorcraft transmission systems.

Technology Taxonomy Mapping:
(NASA's technology taxonomy has been developed by the SBIR-STTR program to disseminate awareness of proposed and awarded R/R&D in the agency. It is a listing of over 100 technologies, sorted into broad categories, of interest to NASA.) Composites

The Phase 2 effort will be used to advance the material and design technologies that were explored in the Phase 1 study of hybrid gears. In this hybrid approach, the conventional metallic web is replaced with a composite element. This alternative design generates a significant weight reduction and the potential for the reduction of noise and vibration. The Phase 2 program will make the first large scale hybrid gears that can be run in a rotating gear rig with imposed torque loading. Several full scale gears will be made as well as full scale test elements. Test results from full scale testing will be applied to computer simulation models. This effort will apply topology optimization techniques to predict the best design of the gear elements. This should enable significantly more efficient designs than those fabricated and tested in the Phase 1 program. This program will also explore a power transmission system that integrates gear and shaft into a single structure. It is hoped that this integrated system will benefit weight, noise and tolerance of misalignments.

Potential NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) This research offers many attractive benefits for rotorcraft systems. These benefits include large weight savings which directly corresponds to increased performance. This research also potentially decreases the amount of individual parts in the gearbox system, by co-molding and directly attaching features. Decreased parts directly affect maintenance costs and intervals. These benefits would be beneficial to both NASA applications as well as commercial rotorcraft systems. There is virtually no rotorcraft system that couldn't incorporate this research into their existing or new systems.



Potential NON-NASA Commercial Applications:
:
(Limit 1500 characters, approximately 150 words) While the focus of this work is on rotorcraft, if proven successful this technology could be applied to gears across many consumer industries such as industrial and automotive.

Technology Taxonomy Mapping:
(NASA's technology taxonomy has been developed by the SBIR-STTR program to disseminate awareness of proposed and awarded R/R&D in the agency. It is a listing of over 100 technologies, sorted into broad categories, of interest to NASA.) Composites