Analysis of Large-Scale Hybrid Aerospace Spur Gear Drivetrains

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The hybrid gear concept, which combines a metallic outer rim of gear teeth with a composite web, has shown potential to reduce the weight of small-scale spur gears without negatively affecting vibration performance for low- and medium-speed applications. In this paper, the hybrid gear design and tooth microgeometry optimization technique that had been applied to small-scale spur gears was adapted for application to spur gears of aerospace-relevant scale, speed, and load. A single reduction drivetrain model was developed featuring large-scale hybrid spur gears, which was used to determine optimal tooth microgeometry modifications that minimized peak-to-peak transmission error. Static and dynamic transmission error analyses were then performed using the optimal microgeometries. Results were compared to those predicted for a similarly-optimized all-steel drivetrain. The application of optimal tooth microgeometries to large-scale hybrid gears led to a more significant decrease in a peak-to-peak transmission error than was observed for the small-scale gears. Similar to results for small-scale hybrid gears, the drivetrains featuring large-scale hybrid gears predicted similar dynamic transmission errors to their all-steel counterparts at low and medium speeds, while significantly different transmission errors were predicted at high speeds.

Original languageEnglish (US)
Article number012004
JournalJournal of the American Helicopter Society
Issue number1
StatePublished - Jan 2023

All Science Journal Classification (ASJC) codes

  • General Materials Science
  • Aerospace Engineering
  • Mechanics of Materials
  • Mechanical Engineering


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