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Spline Health Prognosis via Physics Based Modeling Coupled with Component Level Tests
Navy SBIR 2009.3 - Topic N093-170 NAVAIR - Mrs. Janet McGovern - [email protected] Opens: August 24, 2009 - Closes: September 23, 2009 N093-170 TITLE: Spline Health Prognosis via Physics Based Modeling Coupled with Component Level Tests TECHNOLOGY AREAS: Air Platform, Materials/Processes ACQUISITION PROGRAM: PMA-299, H-60 Helicopter Program OBJECTIVE: Develop physics based spline health prognosis models for fretting fatigue and crack propagation failure modes. DESCRIPTION: The algorithms that are currently employed for determining spline health are rudimentary and are primarily empirically derived from health monitoring sensor data obtained from system or subsystem component tests. These algorithms mainly rely on rotational speed and tooth meshing frequencies, or are statistical in nature. The physics based models of spline faults developed under this topic should include fretting fatigue failure modes as well as crack propagation into the bulk stress area of the component. The physics based models should account for specific characteristics of the splines being modeled including geometry, alloy composition and materials characteristics, residual stress, case and core hardnesses, case depth, ratio of case thickness to tooth thickness, surface finish and machining characteristics. These models must be able to be updated via sensor feedback from operating spline tests. Test to failure of the modeled splines is required in order to refine the models, to demonstrate the ability to calibrate the models via sensor feedback, and to validate the ability of the models to accurately quantify the current health state and predict remaining useful life. PHASE I: Design and develop physics based spline health models to quantify fretting fatigue as well as crack initiation and propagation failure modes. Develop and demonstrate proof of concept models and associated state awareness sensors that are capable of making the required health assessments of spline health. PHASE II: Refine the models for accuracy by accounting for geometry, alloy composition and materials characteristics, residual stress, case and core hardnesses, case depth, ratio of case thickness to tooth thickness, surface finish and machining characteristics. Conduct demonstration tests to characterize the capability of the models to accurately quantify the current state and to predict the remaining useful life of the modeled components. Refine the models as necessary and validate via test. PHASE III: Conduct necessary qualification testing and finalize the physics based spline health prognosis models for transition to both military and commercial applications. PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: The physics based spline health prognosis models developed under this topic would significantly enhance the state of the art for commercial aviation. The technology is directly transferable to military and commercial gearbox applications. REFERENCES: 2. Advanced Vibration Analysis to Support Prognosis of Rotating Machinery Components. KEYWORDS: Spline; Prognostics; Models; Pitting; Spalling; Fatigue
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