Meshed Spur Gear Power Loss. Test Results
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1 T04:45:34+00:00Z National Aeronautics and Space Administration The Effectiveness of Shrouding on Reducing Meshed Spur Gear Power Loss Test Results I. R. Delgado (NASA) and M. J. Hurrell (HX5 Sierra) AGMA 2017 Fall Technical Meeting Columbus, Ohio, USA, October 22-24,
2 Windage power loss (WPL) Definition Drag on gear Viscous drag on gear faces Air/Oil impingement on tooth surface (inertia effects) Category load-independent, spin-loss Significance Occurs at greater than 10,000 ft./min. (51 m/s) Gearbox efficiency losses Reduced rotorcraft performance (i.e. payload, range) Ref: Hill, Matthew J., et al. "CFD analysis of gear windage losses: Validation and parametric aerodynamic studies." Journal of Fluids Engineering (2011):
3 Shrouded Spur Gear WPL Work (1984) Dawson: Windage Loss in Larger High-Speed Gears single spur gears, air reduction in WPL with axial and radial shrouding (1998) Lord: An Experimental Investigation of Geometric and Oil Flow Effects on Gear Windage and Meshing Losses single and meshed spur gears, shrouding, air/oil decrease in WPL with increasing oil temp., increase in WPL with increasing oil flow (2011) Combined Analysis & Experimental Validation single spur gear analyses, shrouding Hill: CFD Analysis of Gear Windage Losses. Handschuh: Initial Expts. of High-Speed Drive Sys. Windage Losses (2017) Delgado and Hurrell: Experimental Investigation of Shrouding on Meshed Spur Gear Windage Power Loss 7x to 12x increase in WPL for meshed spur gears compared to single spur gears (2017) Delgado and Hurrell: Baseline Experimental Results on the Effect of Oil Temperature on Shrouded. WPL sensitivity to oil flow rate and oil temperature 3
4 Comparison - Shrouded Spur Gear WPL Data Reference Effect of Shrouding on WPL Notes environment clearance radial axial [in] [in] Dawson [5] 53% 1, 2 air n ? Handschuh et al. [6] ~38% 2 air n , Lord [8] ~80% 2 air n , Lord [8] ~10X 3 oil jet 0.66 gpm n , Delgado et al. [11] 7x 4 oil jet ~0.7 gpm y ,000 n/a n/a Delgado et al. [11] 12x 5 oil jet ~0.9 gpm y Notes 1) 270 shroud sector 2) WPL comparison relative to unshrouded configuration. 3) WPL comparison relative to shrouded configuration in air. 4) WPL compared to single unshrouded of Handschuh et al. [6] 5) WPL compared to single shrouded of Handschuh et al. [6] meshed spur gear? diametral pitch face width [in] speed [ft./min.]
5 Comparison - Shrouded Spur Gear WPL Data Reference Effect of Shrouding on WPL Notes environment clearance radial axial [in] [in] Dawson [5] 53% 1, 2 air n ? Handschuh et al. [6] ~38% 2 air n , Lord [8] ~80% 2 air n , Lord [8] ~10X 3 oil jet 0.66 gpm n , Delgado et al. [11] 7x 4 oil jet ~0.7 gpm y ,000 n/a n/a Delgado et al. [11] 12x 5 oil jet ~0.9 gpm y Notes 1) 270 shroud sector 2) WPL comparison relative to unshrouded configuration. 3) WPL comparison relative to shrouded configuration in air. 4) WPL compared to single unshrouded of Handschuh et al. [6] 5) WPL compared to single shrouded of Handschuh et al. [6] meshed spur gear? diametral pitch face width [in] speed [ft./min.]
6 Comparison - Shrouded Spur Gear WPL Data Reference Effect of Shrouding on WPL Notes environment clearance radial axial [in] [in] Dawson [5] 53% 1, 2 air n ? Handschuh et al. [6] ~38% 2 air n , Lord [8] ~80% 2 air n , Lord [8] ~10X 3 oil jet 0.66 gpm n , Delgado et al. [11] 7x 4 oil jet ~0.7 gpm y ,000 n/a n/a Delgado et al. [11] 12x 5 oil jet ~0.9 gpm y Notes 1) 270 shroud sector 2) WPL comparison relative to unshrouded configuration. 3) WPL comparison relative to shrouded configuration in air. 4) WPL compared to single unshrouded of Handschuh et al. [6] 5) WPL compared to single shrouded of Handschuh et al. [6] meshed spur gear? diametral pitch face width [in] speed [ft./min.]
7 Comparison - Shrouded Spur Gear WPL Data Reference Effect of Shrouding on WPL Notes environment clearance radial axial [in] [in] Dawson [5] 53% 1, 2 air n ? Handschuh et al. [6] ~38% 2 air n , Lord [8] ~80% 2 air n , Lord [8] ~10X 3 oil jet 0.66 gpm n , Delgado et al. [11] 7x 4 oil jet ~0.7 gpm y ,000 n/a n/a Delgado et al. [11] 12x 5 oil jet ~0.9 gpm y Notes 1) 270 shroud sector 2) WPL comparison relative to unshrouded configuration. 3) WPL comparison relative to shrouded configuration in air. 4) WPL compared to single unshrouded of Handschuh et al. [6] 5) WPL compared to single shrouded of Handschuh et al. [6] meshed spur gear? diametral pitch face width [in] speed [ft./min.]
8 Comparison - Shrouded Spur Gear WPL Data Reference Effect of Shrouding on WPL Notes environment clearance radial axial [in] [in] Dawson [5] 53% 1, 2 air n ? Handschuh et al. [6] ~38% 2 air n , Lord [8] ~80% 2 air n , Lord [8] ~10X 3 oil jet 0.66 gpm n , Delgado et al. [11] 7x 4 oil jet ~0.7 gpm y ,000 n/a n/a Delgado et al. [11] 12x 5 oil jet ~0.9 gpm y Notes 1) 270 shroud sector 2) WPL comparison relative to unshrouded configuration. 3) WPL comparison relative to shrouded configuration in air. 4) WPL compared to single unshrouded of Handschuh et al. [6] 5) WPL compared to single shrouded of Handschuh et al. [6] meshed spur gear? diametral pitch face width [in] speed [ft./min.]
9 WPL Research Spur Gear, Air-Oil Experimental Analytical Single Spur Gear Meshed Spur Gears Unshrouded Shrouded Unshrouded Shrouded Handschuh (2011) Polly (2013) Hill (2012) Kunz (2012) Chaari (2012) Gorla (2012) Lord (1998) Handschuh (2011) Hill (2012) Kunz (2012) Petry-Johnson (2008) Seetharaman (2009) Polly (2013) Delgado (2017) Seetharaman (2009) Burberi (2016) Delgado (2017) None
10 Focus of this Effort Obtain WPL experimental data on meshed spur gears at intermediate shroud conditions Constant oil inlet temperature: 100 F (38 C) Constant oil pressure and flow 4 shroud configurations Max axial, Max radial Min axial, Min radial Max axial, Min radial Min axial, Max radial Identify WPL trends, if any Suggestions for additional research 10
11 NASA Windage Power Loss Test Rig dc motor: 150 hp (112 kw) speed-up gearbox: 1:5.17 ratio torque-meter: 2,000 in-lbs (226 N-m) Eddy-current brake: 73.8 ft.-lb. (100 N-m) at 2865 rpm (300 rad./sec.) Friction clutches Disengage test gearbox from drive/brake system Into-mesh lubrication Measurements shaft speed gear fling-off temperature gear mesh oil flow oil inlet/exit temperature Test gearbox Torquemeter Speed-up gearbox Friction clutches Eddy-current brake Drive motor 11
12 Gear Information Gear Parameter Drive-side Driven-side Number of teeth Pitch / module, 1/in. (mm) 4 (6.35) Face Width in. (mm) Pitch Diameter, in. (mm) 1.12 (28.4) 11.0 (279.4) 1.12 (28.4) 13.0 (330.2) Pressure Angle, deg. 25 Outside Diameter, in. (mm) Material (291.85) (342.65) Steel-SAE 5150H 12
13 Shrouding Assembly 13
14 Shrouding Assembly 14
15 Shrouding Assembly 15
16 Shrouding Configurations Axial Clearance Radial Clearance Windage Rig Schematic Shroud Configuration Per side [inches] (mm) Drive [inches] (mm) Driven [inches] (mm) (U) Unshrouded w/o clamshell housing (CS) Unshrouded w/ clamshell housing 2.25 (57) 2.5 (64) 1.0 (25.4) 1.5 (38) 0.8 (21) 0.8 (21) Top View (C36) shrouded 1.2 (31) 0.66 (17) 0.66 (17) (C1) shrouded 0.04 (1) 0.04 (1) 0.04 (1) (C6) shrouded 0.04 (1) 0.66 (17) 0.66 (17) Driven Drive (C31) shrouded 1.2 (31) 0.04 (1) 0.04 (1) Front View 16
17 Shrouding Configurations Axial Clearance Radial Clearance Windage Rig Schematic Shroud Configuration Per side [inches] (mm) Drive [inches] (mm) Driven [inches] (mm) (U) Unshrouded w/o clamshell housing (CS) Unshrouded w/ clamshell housing 2.25 (57) 2.5 (64) 1.0 (25.4) 1.5 (38) 0.8 (21) 0.8 (21) Top View (C36) shrouded 1.2 (31) 0.66 (17) 0.66 (17) (C1) shrouded 0.04 (1) 0.04 (1) 0.04 (1) (C6) shrouded 0.04 (1) 0.66 (17) 0.66 (17) Driven Drive (C31) shrouded 1.2 (31) 0.04 (1) 0.04 (1) Front View 17
18 Shrouding Configurations Axial Clearance Radial Clearance Windage Rig Schematic Shroud Configuration Per side [inches] (mm) Drive [inches] (mm) Driven [inches] (mm) (U) Unshrouded w/o clamshell housing (CS) Unshrouded w/ clamshell housing 2.25 (57) 2.5 (64) 1.0 (25.4) 1.5 (38) 0.8 (21) 0.8 (21) Top View (C36) shrouded 1.2 (31) 0.66 (17) 0.66 (17) (C1) shrouded 0.04 (1) 0.04 (1) 0.04 (1) (C6) shrouded 0.04 (1) 0.66 (17) 0.66 (17) Driven Drive (C31) shrouded 1.2 (31) 0.04 (1) 0.04 (1) Front View 18
19 Shrouding Configurations Axial Clearance Radial Clearance Windage Rig Schematic Shroud Configuration Per side [inches] (mm) Drive [inches] (mm) Driven [inches] (mm) (U) Unshrouded w/o clamshell housing (CS) Unshrouded w/ clamshell housing 2.25 (57) 2.5 (64) 1.0 (25.4) 1.5 (38) 0.8 (21) 0.8 (21) Top View (C36) shrouded 1.2 (31) 0.66 (17) 0.66 (17) (C1) shrouded 0.04 (1) 0.04 (1) 0.04 (1) (C6) shrouded 0.04 (1) 0.66 (17) 0.66 (17) Driven Drive (C31) shrouded 1.2 (31) 0.04 (1) 0.04 (1) Front View 19
20 Shrouding Configurations Axial Clearance Radial Clearance Windage Rig Schematic Shroud Configuration Per side [inches] (mm) Drive [inches] (mm) Driven [inches] (mm) (U) Unshrouded w/o clamshell housing (CS) Unshrouded w/ clamshell housing 2.25 (57) 2.5 (64) 1.0 (25.4) 1.5 (38) 0.8 (21) 0.8 (21) Top View (C36) shrouded 1.2 (31) 0.66 (17) 0.66 (17) (C1) shrouded 0.04 (1) 0.04 (1) 0.04 (1) (C6) shrouded 0.04 (1) 0.66 (17) 0.66 (17) Driven Drive (C31) shrouded 1.2 (31) 0.04 (1) 0.04 (1) Front View 20
21 Shrouding Configurations Axial Clearance Radial Clearance Windage Rig Schematic Shroud Configuration Per side [inches] (mm) Drive [inches] (mm) Driven [inches] (mm) (U) Unshrouded w/o clamshell housing (CS) Unshrouded w/ clamshell housing 2.25 (57) 2.5 (64) 1.0 (25.4) 1.5 (38) 0.8 (21) 0.8 (21) Top View (C36) shrouded 1.2 (31) 0.66 (17) 0.66 (17) (C1) shrouded 0.04 (1) 0.04 (1) 0.04 (1) (C6) shrouded 0.04 (1) 0.66 (17) 0.66 (17) Driven Drive (C31) shrouded 1.2 (31) 0.04 (1) 0.04 (1) Front View 21
22 Windage Power Loss Test Procedure Ramp up 2000 rpm increments every 100 seconds Up to 10,000 rpm (1047 rad/s) Spin-down at 10,000 rpm (1047 rad/s) disengage via clutches the drive motor and dynamometer Record speed vs time Repeat 2x for 3 cycles total. Oil Inlet Temperature: 100 F (38 C) Shroud Config U, CS, C1, C6, C31, C36 22
![Windage Power Loss Calculation WPL = P total - P gear mesh - P driveline losses P total = ( system [ft-lbf] x N[rpm]) 5252 system = I system x system I system (equivalent inertia for meshed spur](/docs-images/111/198210189/images/23-1.jpg "gears) system via experiment P gear mesh (estimated via NASA TP 1622, minimal, 1%) P driveline losses = ( driveline [ft-lbf] x N[rpm]) 5252 driveline = I driveline x driveline I driveline (curved")
23 Windage Power Loss Calculation WPL = P total - P gear mesh - P driveline losses P total = ( system [ft-lbf] x N[rpm]) 5252 system = I system x system I system (equivalent inertia for meshed spur gears) system via experiment P gear mesh (estimated via NASA TP 1622, minimal, 1%) P driveline losses = ( driveline [ft-lbf] x N[rpm]) 5252 driveline = I driveline x driveline I driveline (curved rail method by Genta) driveline via experiment 23
24 Effect of wind-down cycles on WPL
25 Avg. Oil Temps. and Oil Flows vs. Shroud Configuration Shroud Configuration oil inlet temp. [ F] ( C) oil out temp. [ F] ( C) gear oil-flow [gpm] (lpm) bearing oil-flow [gpm] (lpm) (U) unshrouded 107 (41) 163 (73) 0.91 (4.1) 0.27 (1.2) (CS) unshrouded with clam-shell housing 102 (39) 162 (72) 0.90 (4.1) 0.14 (0.6) (C1) shrouded 109 (43) 143 (62) 0.91 (4.1) 0.18 (0.8) (C6) shrouded 107 (41) 151 (66) 0.91 (4.1) 0.19 (0.9) (C31) shrouded 101 (38) 137 (58) 1.07 (4.9) 0.18 (0.8) (C36) shrouded 101 (38) 144 (62) 0.85 (3.9) 0.19 (0.9)
26 WPL versus Shroud Configuration Windage Rig Schematic Top View Driven Drive Front View
27 WPL versus Shroud Configuration Windage Rig Schematic Top View Driven Drive Front View
28 WPL versus Shroud Configuration Windage Rig Schematic Top View Driven Drive Front View
29 WPL versus Shroud Configuration Windage Rig Schematic Top View Driven Drive Front View
30 WPL versus Shroud Configuration Windage Rig Schematic Top View Driven Drive Front View
31 WPL versus Shroud Configuration Windage Rig Schematic Top View Driven Drive Front View
32 WPL Repeatability: C31 configuration C31 C31 Repeat Avg. Oil Inlet Temp. [ F] Avg. Oil Inlet Flow [gpm]
33 Conclusions & Further Work Conclusions Shrouding effectiveness negligible on WPL below 15,000 ft./min. 10% decrease in WPL with small axial, small radial clearance shrouds 29% decrease in WPL for large axial, small radial clearance shrouds Further Work Plans to test a modified shroud configuration Plans to determine location of maximum pressure near the mesh point Other In-to-mesh vs out-of-mesh oil flow Oil jet size, position Oil drain hole geometry, position
34 Acknowledgements NASA Revolutionary Vertical Lift Technology (RVLT) Project Dr. Robert F. Handschuh Sig Lauge HX5 Sierra, Technical Test Support 34
35 Appendix 35
36 Helicopter Performance Chart Ref: FAA Helicopter Flying Handbook, Chapter 7. Torque required for cruise or level flight, Figure
37 Helicopter Performance Chart Ref: FAA Helicopter Flying Handbook, Chapter 7. Torque required for cruise or level flight, Figure
38 Helicopter Performance Chart Ref: FAA Helicopter Flying Handbook, Chapter 7. Torque required for cruise or level flight, Figure
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