. NASA ...................................... _ ...... _.... AVSCOM ....

Technical -Memorandum 102441 ..... _echn_cal Memorandum 89-C-010 - ......

:_'_o_-::-,,- :_iAssessment of Worm Gearing i

for Helicopter Transmissions

Lev Chaiko
ProPulsion Directorate
............ U.S. Army Aviation Research and Technology Activity--AFSCOM
Lewis Research Center
Cleveland, Ohio ........

January 1990

SYSTEMS COMMAND
AVIATION
.... _.................................. - .............. - ...... - -c._ AVIATIONng ACTiVII"Y
.........

_ (NASA-T_-102441) ASSESSMENT OF _ORM GEARING

.-, FOR HFLIC_PTER TRANSMTSSIONS Nq0-15973
(NASA) l& p
CSCL 1 3T

Uncl as
G3/07 020109_5
 ASSESSMENT OF WORMGEARING FOR HELICOPTER TRANSMISSIONS

Lev Chalko
Propulsion Directorate
U.S. Army Aviation Research and Technology Activity - AVSCOM
Lewis Research Center
Cleveland, Ohio 44135

SUMMARY

Thls report assesses a hlgh-efflclency hydrostatic worm gear drive for

helicopter transmissions. The example given Is for a large cargo helicopter
C'J with three 4000-kW engines and a transmission reduction ratio of 110. The re-
C_J port also contains an efficiency calculation, a description of the test stand
LO
I for evaluatlng the feasibility of worm gear hydrostatic mesh, a weight calcula-
i,i
tion, and a comparison with conventional hellcopter transmlsslons of the same
power and transmlsslon reduction ratio.

INTRODUCTION

Gear trains are extensively used In mechanical systems, but in no other

transport vehicle Is the relative welght of the transmission as great as In
the helicopter. The transmission system Is the helicopter's most complex and
expensive assembly and requires the most labor-lntenslve maintenance. In addl-
tlon, the weight of the transmission Is comparable to that of the fuselage.
Any substantial progress In the quallty of helicopters will most likely come
through Improvements in their transmission systems. Worm gearing Is very
attractlve for use in helicopter transmissions because it can transmit torque
from the horizontal engine shaft to the vertical rotor shaft, reducing the rev-
olutions by any ratio necessary In one stage. Transmission reduction ratlos
for existing helicopters average from 60 to 110. Using thls otherwise advanta-
geous worm gearing In helicopter gearboxes has long been prevented by a serlous
problem: low efficiency due to sliding frlctlon between worm gear teeth and
worm coils. Creation of a worm-gearlng helicopter transmission Is contingent
upon reducing this friction. There are four ways to eliminate friction between
two surfaces:

(l) By uslng bail or roller bearings

(2) By creating an aerostatlc clearance between the planes
(3) By creatlng an electromagnetic clearance between the planes
(4) By creatlng a hydrostatic clearance between the planes

The highest Ioad-carrylng worm gear is the double-enveloping worm gear

(globoldal worm gear or "cone drive" worm gearing, ref. l). Thls study consid-
ers only the hydrostatic double-enveloplng worm gear transmlsslon. In this
transmisslon, friction Is decreased by pumping the oil through meshes between
worm gear teeth and worm coils under high pressure. This high oll pressure
creates a lift force that separates the surfaces of the worm gear teeth from
the worm coils. The sum of these llft forces from several meshes creates a
torque on the worm gear and an axial force on the worm. In order to react to
this axlal force, the worm needs a counteracting hydrostatic bearlng (flg. l).
The efficiency of the hydrostatic worm gear transmlsslon Is determined by the
 frlctlon losses of a11 these hydrostatic meshesand the power losses of the oii
pumping systems.

SYMBOLS

A hydrostatic mesh area

Al land area

Ap pocket area

B slot width

F load Force per worm gear tooth

Ff Friction Force In hydrostatic mesh

h slot height (clearance)

K volume of part

N total power loss

Nf Friction power losses in hydrostatic mesh

Np pump power

n shaft speed, rpm

Q oll flow

Pp oil pressure at pump

Px pressure needed to create 11ft force of 57 706 N on one tooth

R worm gear radius

S slot length

T torque

V veloclty In hydrostatic mesh

W weight

c{x helix angle of worm

n oil viscosity

p pitch of worm
 Subscripts:

c worm col]

d disk

g worm gear

opt optimum

t tooth

tot total

w worm

EXAMPLE" LARGE CARGO HELICOPTER TRANSMISSION

As an example let us assume a large cargo helicopter has three gas turblne
englnes (4000 kW each), and the engine shafts rotate at 14 280 rpm. The main
shaft of the hellcopter combines the power of these three gas turbine engines
by using three Input modules and three worm meshes (fig. 2). If the maln rotor
speed Is 130 rpm, the transmlsslon reduction ratlo is 14 280/130, or llO. The
maln rotor torque per worm Is

N
T-- . 288 531 N.m
n

If the worm gear radius R Is l m, the total force for one worm Is

F = _T = 288 53l N

Each worm gear mesh has flve teeth In engagement; therefore, the load force per
tooth F equals 57 706 N. The working surface of the worm gear tooth looks
llke a horseshoe; part of It Is a hydrostatic pocket and the rest Is land.
The oll pressure is at Its maximum In the pocket and gradually drops to zero
from the pocket edge to the perimeter of the horseshoe (fig. 3).

Determlnatlon of Optimum Clearance, Efficlency, and Oil Viscosity

The optimum clearance, efficiency, and oll vlscoslty were calculated for
the condltlons that take place on a hydrostatlc bearing test stand (see refs. 2
and 3):

Oil flow, Q : 10.5 gal/min (39 llters/min)

Oil pressure at pump, Pp , 5000 psl (350 bar)

Hydrostatic mesh area, A : 87 cm 2

Pocket area (fig. 3), Ap , 23 cm 2

 Land area (fig. 3), Al = 64 cm2

Slot width, B , 1.5 cm

Slot length, S = 23.3 cm

Slot helght (mlnlmum boundary film), h = 0.25 mm (0.025 cm)

0ii vlscoslty, n : 50 cP (5xlO -6 N.s/cm 2)

Velocity in centerllne of hydrostatic mesh, V = 5800 cm/s

The oil flow through a hydrostatlc worm gear mesh Is constant.

Q =
2)
12nS = Constant

Hence

Pph 3 : Constant

Pump power Is given by

where 0.8 Is the efficiency of the pump.

p2h3 B
_E___
Np = 9.6nS

Power loss due to friction In a hydrostatic gear mesh is

Nf = FfV

where Ff force of friction in the hydrostatic mesh

Ff " nVA
h

Or

NF = """h = 4.15 kW

One worm has flve hydrostatlc gear meshes and one hydrostatic counterforce
bearlng. If the frlction losses in the counterforce hydrostatic bearlng are
three times greater than that of one worm gear mesh, the friction power losses
of the worm will be

Nf : 4.15 × 5 + 4.15 x 3 : 33.2 kN

4
 The total power loss in a hydrostatic gear mesh equals the sumof the fr|ct|on
power losses and the pumppower losses"

N : _ Np + _ Nf

p2h3B nV2A]
N= P
9.6nS + h

The geometrlcal sizes B, S, and AI, the pressure Pp and the velocity are
constant, and therefore

h3
= -- + Constant rl
N Constant n h

Clearance. - The optimum clearance (hgp t) can be found from a derivative

of the f--un--ct-_onal
dependence of the power losses on the clearance"

p2_.2
pmJnop t nV2A l
=0
9 6nS 2
• hop t

then

4 3.2 5xlO -6) x 58002 x 64 x 23.3 x 3.2

h°pt = n2V2Al S _/( 2 35002 x 1.5

= 0.0216 cm (0.22 mm)

Hence, for the glven appl|catlon the optimum mesh clearance Is 0.22 mm
(fig. 4).

Efficlenci. - The worm gear mesh efflclency may now be calculated. The
pump power fs

p_h3B
Np - 9.6nS

The pressure Px needed to create a lift force of 57 706 N on one tooth of the
worm gear can be found as

PxAI
PxAp + _ = 57 706 N

or

57 706
Px = 23 + 32 - 1049 N/cm 2
 The pumplng power required Is

10492 x 0.0223 x 1.5

= 16 419 N.cm/s (O.16 kW)
Np = 9.6 x 5xlO -6 x 22.3

The engagement of a worm gear transmission Involves five teeth and one counter-
force bearing. This counterforce bearing uses three tlmes more o11 than one
tooth of the hydrostatic worm gear mesh, and therefore pump power losses of the
worm gear mesh can be calculated as

__Np : (5 + 3) x 0.16 . 1.28 kW

The total power losses on one worm, Including friction and pump power losses,
are

N , _Nf + _Np = 33.2 + 1.28 : 34.48 KW

Engine power Is 5350 hp, or 4000 kW. The efficiency of the hydrostatic worm
gear transmlsslon is
100 - 34.48 x I00 99 14 percent
4000 " "

Oil viscosity. - The optimum oli viscosity was determined as follows

<ref. 2)" The total power losses In the hydrostatic gear mesh were found as

p2,3_
N - _ nV2Al
- 9.6nS + h

The optimum oll vlscos|ty can be found from a derlvatlve of the functional
dependence of the worm gear power losses on the o|I viscosity at maximum worm
gear efficiency dN/dn = 0 and then

p_h3B V2 AI
-0
2 6S h
nopt 9"

or

p2h4_
p m = V2AI nopt
2 9 .6S

= 3xi0 -6 N.slcm 2
n°pt \V2AI S9.6/

HYDROSTATIC WORMGEAR MESH TEST

The goals of a hydrostatic worm gear mesh test are"

(I) Determination of the optimum clearance hop t corresponding to the

highest efficiency of the hydrostatic worm gear mesh for tilt and paral-
lel surfaces of a worm gear tooth
6
 (2) Determination of the optlmum posltlon of a pocket on the surface of a
wormgear tooth and the optimum shapes of the pocket and the "horseshoe"

(3) Determination of the optimum ol] viscosity

All these parameters can be experimentally determined on a hydrostatic bearlng

test stand. The surface of the worm coils Is a globoldal helix, where the
helix angle gradually changes from coil to coil. The helix angle for any posl-
tlon of engagement(ref. 4) is

_x = arctan --P--
_dx

where p is the pitch of the worm. At the best efficiency the surfaces of the
worm gear teeth should be parallel to the surfaces of coils -1 and ] (fig. 1).
In thls case worm gear teeth have a minimum tilt angle with neighboring colls
O, -2, and 2 (fig. I).
The efficiency test is conducted on a model representing a worm gear tooth
(horseshoe). Two of the horseshoes are Installed in a frame (caliper) facing
the disk with clearance h (fig. 5). The hlgh-speed rotating disk imitates a
coii of the worm. High-pressure oli flow is pumpedthrough the clearance
between the disk and the horseshoes (flg. 5). The oli pressure of the hydrau-
lic system and the oi] flow will determine the pumppower. The load force is
measured by a strain gage on the callper. The friction forces of the hydro-
static meshesare measured by a friction force gage. The horseshoes can be
installed with different clearances and at dlfferent tllt angles to the rotat-
Ing dlsk. Also, horseshoes of dlfferent shapes and with different pocket posi-
tions will be tested. The results of these tests w1]] show the experlmental
dependenceof the hydrostatic worm gear transmlsslon efficiency on these
factors.

Optimum vlscoslty tests must _Iso be conducted. The theoretical viscosity

was calculated as 3.00xlO -° N.s/cm L. In a real sltuatlon the oi1 in the worm
gear mesh will be heated as the power losses are converted to heat. Thls heat
will be distributed among the coils of the worm, the worm gear teeth, and the
oll fllm In the engagement. The oll fllm temperature w111 Increase and the
real viscoslty will decrease. The test for experimental determination of the
optlmum o11 vlscoslty should be conducted with constant clearance and o11 flow
but varlable oll viscosity.

CALCULATION OF HYDROSTATIC WORM GEAR TRANSMISSION WEIGHT

The welght of a hydrostatlc worm gear transmission strongly depends on the

pressure of the hydraullc system. In some Industrial hydraulic systems, oil
pressure can be 30 000 psi (2000 bar), The following calculation of the worm
gear transmission weight is made for a 15 OOO-psl (lO00-bar) hydraulic pres-
sure. Such hlgh pressure occurs In the short line connectlng the hydraulic
cylinder and a worm gear tooth for a short tlme during the full-load takeoff
of the hellcopter. For the three-englne helicopter the power of one englne is
4000 kW and maln rotor speed is 130 rpm. The worm gear torque is

T : 4xi06 x 60 = 288 218 N.m

2_ x 130
 If the wormgear radius R Is 0.75 m, the force from one worm Is
288 218
_F , 0.75 - 384 290 N

This force Is distributed among five worm gear teeth so that the force on one
tooth Is

384 290
F z - 76 858 N = 7834 kg

Next we wlll calculate the area of a pad (horseshoe) when the hydraulic
pressure Is 15 000 psl (1000 bar) and the pocket area Is lO percent of the pad
area A - the remaining 90 percent of the pad area being land. The load force
created by hydrostatic pressure In the pocket is ApP. The load force created
by hydrostatic pressure in the land is AIP/3. The load force for the entire
pad Is

AlP
ApP + _ = 7834 kg

Ap 0.1 A; A l = 0.9 A; P : I000 kglcm 2

0.9 A x lO00
0.I A x 1000 + = 7834

A = 20 cm 2

The tooth volume (flg. 6) Is given by

Kt ffi 2_r(R2x + 4 r) (3.5 + 20"5) x 3 = 42.4 cm3

Hence, the volume of the 11_ teeth is 4665 cm 3. The volume of the rim wlll be

three tlmRs more (14 000 cmJ). The total volume of the worm gear thus Is
18 665 cm j. If the worm=gear Is made of tltanlum (density, 4.5 g/cm3), the
weight of the worm gear Is Wg - 18 665 x 4.5 = 84 000 g (84 kg, or 185 Ib)

The dlsk volume (fig. 7) Is

K d = 29 450 cm 3

The welght of the tltanlum dlsk Is

Wd : 29 450 x 4.5 = 132 000 g (132 kg, or 290 ]b)

The volume of a worm coll is four times greater than the volume of a worm
gear tooth:

Kc : 42.4 x 4 = 170 cm 3

The volume of a counterforce hydrostatic bearing Is twice as great as the vol-

ume of one coil. A worm comprises flve coils and one counterforce hydrostatic
bearing. The total volume equals
 Kw = 5K c + 2K c = 7 x 170 = 1190 cm3

The worm shaft and _earlngs double the volume, and the weight of the steel worm
(density, 7.85 g/cm J) Is g|ven by

Ww : 2.1190 x 7.85 = 18.683 g (18.7 kg, or 41 Ib)

Hydrostatic worm gearing comprises a worm gear wheel, a disk, and three worms.
Its welght Wt equals"

Wt = 84 + 132 + 3 x 18.7 = 272 kg

The welght of the hlgh-pressure hydraullc system cannot be estlmated until

the optlmal deslgn of the hydrostatic worm gear mesh is found. Assuming that
the weight of the hlgh-pressure hydraullc system doubles the weight of the
transmisslon, we calculate that this transmlsslon weighs 500 kg (II00 Ib).
Input modules of exlstlng hellcopters have transmlssion reduction ratlos from
2.5 to 3.5. The input module ratlo of the hydrostatlc worm gear transmlsslon
equals I, and hence It w111 weigh two-thlrds as much as exlstlng Input modules.
The followlng table compares the welghts of varlous parts and units of the worm
gear transmlsslon wlth those of a representative basellne planetary transmls-
slon havlng the same power and reduction ratio. It Is expected that the worm
gear transmission welght w111 only be about 41 percent that of the basellne
weight.

Baseline Hydrostatic
planetary worm gear
transmission transmission
weight,
Ib

Housing and rear cover 1451 500

Planetary 2146
Worm gear and worms 1100
Bearings 292 255
Gimbal mount 103
Accessory gearbox 22 22
Rear cover accessory 150 150
Sumps and pumps 140 60
Input (right and left modules) 430 300
Input aft 532 150
Rotor drive 853
Scissors and standpipe 66
Total 6185 2537
Savings, percent 0 41

DISCUSSION

Almost all hellcopter gearboxes have three or four stages of gear tralns
with one or two bevel gear stages and one or two spur gear (usually planetary)
stages (i.e., many gears, bearlngs, shafts, and support parts). Gear trains
are extensively used in mechanlcal systems, but In no other transport vehicle
is the relative weight of the transmlsslon as great as in the helicopter. In
recent years there has been progress in Improvlng the quality of helicopter
gearboxes as manufacturing was Improved and new technology and materials were
developed. However, any new steps In thls progress will be more and more dif-
ficult. Obviously, new energy transfer tralns for Improvlng the drive from the
gas turbine to the maln rotor shou]d be Investigated. A hydrostatic worm gear
 transmlsslon could be one such train, since it weighs less than a conventional
gear train transmission. Also, a hydrostat|c contact could have a longer serv-
Ice life and make less noise as well as provides an opportunity to use llght
metals such as titanium, aluminum, and composites. The case where one of the
three engines is Inoperable must be considered for a hydrostatic worm gear
transmission -- tn this case the worm gear must run the worm (i.e., the trans-
mtsslon must be reversible). Reverslbtllty requires that the frlction angle
be less than the mlnlmum helix angle of the worm. For the realization of this
condition the worm gear tooth must have one more hydrostatlc pad on the back
side. This hydrostatic pad could be very small. The lift force of this pad
need be only enough to run the worm, the shaft, and part of the overrunning
clutch.

The hydrau11c system of a hydrostatic worm gear transmission must use

high oll pressure; a plunger o11 pump (fig. 8) is best suited for this purpose.
The hydraulic system of a hydrostatic worm gear transmission conslsts of one
plunger per tooth mounted in the body of the worm gear. As the worm gear ro-
tates, the plungers overrun a cam, which Is an eccentric stationary mounted In
the sector of the gear mesh. The plunger thus dlsplaces oll in the gear mesh
and creates hydrostatic clearance between the worm gear teeth and the worm
coils.

CONCLUSIONS

The results of this analysis of a hydrostatic worm gear transmission

demonstrate:

I. That it could have the same hlgh efficiency as a conventlonal gear

transmission

2. That its benefits Include llghter welght, less noise, greater compact-
ness, longer service 11fe, and low manufacturing and malntenance costs.

Future research and development of thls transmission could open new per-
spectlves for Improvlng power transfer trains. For example, using high o11
pressure (to 30 000 psi) would allow a welght decrease or an efflclency In-
crease in the hydrostatic worm gear transmission.

REFERENCES

I. Cone, S.T.: The Cone Drive, Product Catalog and Englneerlng Manual, Cone
Drlve Operations Inc., Traverse Clty, MI.

2. Stansfleld, F.M.: Hydrostatic Bearlngs for Machine Tools and Similar App11-
catlons. The Machlnery Publishing Co., Ltd., Brighton, England, 1970.

3. Fuller, D.D.: Theory and Practice of Lubricatlon for Englneers. 2nd edl-
tion, Wiley Intersclence, 1984.

4. Litvin, F.L.: Theory of Gearlng. NASA RP-1212, 1989.

10
 X

"_ OIL FLOW

R = 1.00 m

Figure I. - Hydrostatlc worm gearing engagement.

MODULE GAS TURBINE

ENGINE

Figure 2. - Three engines an(I hydrostatic worm gearing helicopter Iransmlsslen.

11
 B

InR_

F'7=r _B cROSsSECTION
[PRESSURE

_p _np_rb _ POCKET pRESSURE

N
A-AC.OSS __ _ _ v
SECTION PRESSURE
DIAGRAM VELOCITY
EFFECT
pRESSURE DIAGRAM

Figure 3. - Surface of worm gem 100th (horseshoe) and pressure diagrams.

zl ._N = Np + N ! //

_-- Np = CONSTANT xCLEA

--_

2 ,1
x_

_.,-..-,ll,,-

Figure 4, - Oependence o! power losses on hydrOStatic clearance.

_2
 r- DISK
i I

GEARBOX

ill
----H Ed_I_Q_
- _lo-t-_-
._'LECTRIE_

_\ _ \_ CALIPER J"
', I I;_ I ,-- WORM GEAR
_ _ TOOTH
_ PRESSURE.. -"
_-- FRICTION FORCE GAGE _ _ FORCE
GAGE
_'-- FLOWMETER

A A

OIL
OIL

Figure 5. - Hydrostatic bearing test stand.

0.5 cm

om- t
Flgure 6. - Shape and cross section of won'n gear tooth.

13
 R (75 cm)

I
"_-- 1 cm

Figure 7. - Worn1 gear disk.

!z
_, _ PLUNGER

__."//,."
I "%.,.

Figure 8. - Hydraulic system of hydrostatic worm gear transmission,

14
 National Aeronautics and
Report Documentation Page
Space Adrninislralion

3. Recipient's Catalog No.

1. Report No. NASA TM-102441 2. Government Accession No.
AVSCOM TM 89-C-010

4. Title and Subtitle 5. Report Date

Assessment of Worm Gearing for Helicopter Transmissions January 1990

6. Performing Organization Code

7. Author(s) 8. Performing Organization Report No.

Lev Chaiko
E-5212

10. Work Unit No.

Performing Organization Name and Address 505-62-OK
NASA Lewis Research Center ILl61102AH45
Cleveland, Ohio 44135-3191
11. Contract or Grant No.
and
Propulsion Directorate
U.S. Army Aviation Research and Technology Activity--AVSCOM
Cleveland, Ohio 44135-3127 13. Type of Report and Period Covered
12. Sponsoring Agency Name and Address
Technical Memorandum
National Aeronautics and Space Administration
Washington, D.C. 20546-0001 14. Sponsoring Agency Code
and

U.S. Army Aviation Systems Command

St. Louis, Me. 63120-1798

15. Supplementary Notes

16. Abstract

This report assesses a high-efficiency hydrostatic worm gear drive for helicopter transmissions. The example
given is for a large cargo helicopter with three 4000-kW engines and transmission reduction ratio of 110. The
report also contains an efficiency calculation, a description of the test stand for evaluating the feasibility of worm
gear hydrostatic mesh, a weight calculation, and a comparison with conventional helicopter transmissions of the
same power and transmission reduction ratio.

17, Key Words (Suggested by Author(s)) 18. Distribution Statement

Worm gear; Hydrostatic bearing; transmission; Unclassified- Unlimited

Efficiency; Weight; Noise Subject Category 07

19. Security Classif. (of this report) 20. Security Classif. (of this page) 21. No. of pages 22. Price*
Unclassified Unclassified 16 A03

NASAFORM1626OCT86 *For sale by the National Technical Information Service, Springfield, Virginia 22161