Design Of Helicopter Gear Mechanism

ISTANBUL TECHNICAL UNIVERSITY
FACULTY OF AERONAUTICS AND ASTRONAUTICS
Mehmet ERGNER B. Burak ZKAHYA Halil KUL SUMMER 2010
DESIGN OF MACHINE ELEMENTS GEAR WHEEL
CONTENTS
Page
General Expression Analysis Of Gear Mechanism Force And Moment Analysis Of The Shafts Dimensional Analysis For The Shafts Selection Of The Bearings Selection Of The Keys Technical Drawing References III V IX XVII XVIII XX XXI XXXII
TABLES AND FIGURES

TABLES Table-1 Lycoming LTS-101-650C-3 Table-2 Bell 222 Specification FIGURES Figure-1 Bell 222 TECHNICAL FIGURES TFigure-1 Shaft 1 Bearing TFigure-2 Shaft 2 Bearing TFigure-3 Shaft 3 Bearing TFigure-4 First Shaft TFigure-5 Second Shaft TFigure-6 Third Shaft TFigure-7 Bevel Pinion TFigure-8 Bevel Gear TFigure-9 Helical Pinion TFigure-10 Helical Gear
XXII XXIII XXIV XXV XXVI XXVIII XXVII XXIX XXX XXXI
III V
IV
Design Of Machine Elements | Asst. Prof. Dr. Halit S. Trkmen
1) GENERAL EXPRESSION
1.1) INTRODUCTION In the late 1960s Bell began designing a new twin turbine engine light helicopter. A mock-up of the new helicopter was displayed in January 1974 at a helicopter convention. Following interest at the convention the company announced the new Bell 222. It was the first light commercial twin turbine engine helicopter developed in the United States. The Bell 222 incorporated a number of advanced features including dual hydraulic and electrical systems, stub wings housing the retractable landing gear, and the Noda Matic vibration reduction system developed for the Bell 214ST. Manufacturing began in 1975. The Model 222 first flew on August 13, 1976. It received certification from the Federal Aviation Administration (FAA) on August 16, 1979 and was approved for visual flight rules (VFR) use on December 20, 1979. Helicopter deliveries began on January 16, 1980. The FAA approved the 222 for single pilot instrument flight rules (IFR) operation on May 15, 1980. This project contains design of a gear-wheel mechanism and analysis of different kinds, which reduces the rotation of an engine in two stages and transmits to the rotor shaft with helical and bevel gears. As a result the gearwheel mechanism that conducts the engine and the main rotor of the helicopter is redesigned.
Table 1 Lycoming LTS-101-650C-3

Symbol Value Unit
Motor Power Turn Reduction Ratio Motor Speed Rotor Speed
P i
2 461 kW 21.91 9597 RPM 438 RPM
Figure-1 Bell 222
1.2) DESIGN The design includes two main rotor blades of stainless-steel-fiberglass construction and rotor hub with elastomeric bearings, which are lubricant free. Its cabin holds a maximum of 10 persons with 1-2 pilots and 8-9 passengers. Seating configurations include standard seating for a pilot and seven passengers; or executive seating with 1-2 pilots and seating for 5-6. The Bell 222 and 230 are usually flown single-pilot (optional dual controls are available), and can be configured for corporate/executive, EMS or utility transport missions. The Bell 222 is powered by twin Lycoming/Honeywell LTS101-650 turbo shaft engines, rated at 592 hp each. Later 222 versions feature more powerful engines. Engine output is at 100% rating, is 9598 RPM. Two independent drive shafts deliver power from the engines to the transmission. The Bell 222's LSTengine exhaust stacks are located at the rear of the engines, while the 230's Allison-engine exhaust stacks are located high on the cowling. Fuel is stored in three tanks, one in the fuselage and one in each sponson. The main rear landing gear retracts into the sponsons.
1.3) SPECIFICATIONS Table 2 Bell 222 Specification Announced 1974 First Flight August 13, 1976 Certified December 1979 Delivered 1980 Seats Front: pilot + one. Main: 46 (depending on seat types) Height Fuselage length Rotor diameter Length overall Engine (2x) Power (2x) Max speed Climb rate Service ceiling Hover ceiling Fuel Capacity Range Empty Weight Maximum Take-off Weight
Maximum 10 (pilot and 9 passengers) 11 ft 8 in (3.56 m) 42 ft 2 in (12.85 m) 40 ft (12.2 m) 49 ft 6 in (15.1 m) Lycoming LTS-101-650C-3 618 hp (461 kW) 130 kt (149 mph, 240 km/h) 1,580 ft/min (8.03 m/s) 12,800 ft (3,901 m) ~9,000 ft (2,743 m) 188+48 US gal (710+182 L) 324 nmi (372 mi, 600 km) 4,555 lb (2,066 kg) 7,848 lb (3,560 kg)
2) ANALYSIS OF GEAR MECHANISM

2.1) FIRST MECHANISM
from this equation; 2.1.1) Pinion of the first mechanism: and from here;
from table 2 from table 3 from table 4
According to fracture; dimension, mm
According to pitting; dimension, mm
From table 13-2 (Mechanical Engineering Design, It can be choose module,
Edition)
Velocity;
For this V value, from table 1
From preferred size table,

For
, , ,
Face Width: 2.1.2) Gear of the first step:
2.2) SECOND MECHANISM
2.2.1) Pinion of the second step: and from here; from table 2 from table 3 from table 4 According to fracture; dimension, mm
According to pitting; dimension, mm
From table 13-2 (Mechanical Engineering Design, It can be choose module,
Edition)
Circumstance velocity;
For this V value, from table 1 According to pitting; dimension, mm
From preferred size table, Face Width: 2.2.2) Gear of the second step: Number of the teeth for gear;
3) FORCE AND MOMENT ANALYSIS OF THE SHAFTS

3.1) FIRST SHAFT
Length of the shaft,
and
and
3.1.1) Moment Diagrams:
Moment Diagram
1200 1000 800 Nm 600 400 200 0 0 50 100 mm 150 149 244 30 200 569 Y Diresction Z Direction 1.111
Moment Diagram For The First Shaft
3.2) SECOND SHAFT
Length of the shaft,
For helical gear;
For bevel pinion;
2338=
2338=
First Region;
Second Region;
Third Region;
3.2.1) Moment Diagrams:
Moment Diagram
1000 0 -1000 -2000 -3000 -4000 -5000 -6000 -7000 -8000 -9000 -10000 0 0 -613 -1.260 -4.765 Y Direction Z Direction -8.684 100 200 mm 300 400 -1.011 -796
Nm
Moment Diagram For The Second Shaft
3.3) THIRD SHAFT
Length of the shaft, Rotor Speed;
First Region;
Second Region;
Moment Diagram
800 600 400 200 0 -200 -400 -600 -800 -1000 -1200 0 50 531 164 X Direction Z Direction -949 100 150 mm 200 250 -958 300
Nm
Moment Diagram For The Third Shaft
4) DIMENSIONAL ANALYSIS FOR THE SHAFTS

4.1) FIRST SHAFT
4.2) SECOND SHAFT
4.3) THIRD SHAFT
5) SELECTION OF THE BEARINGS

5.1) FIRST SHAFT
5.2) SECOND SHAFT
5.3) THIRD SHAFT
6) SELECTION OF THE KEYS

6.1) FIRST SHAFT
Yield Strength 550 MPa=79.8 kpsi Shear Strength
6.2) SECOND SHAFT
6.3) THIRD SHAFT
7) TECHNICAL DRAWING
8) REFERENCES
[1 ] URL-1 en.wikipedia.org/wiki/Bell_222 [2 ] URL-2 http://www.aviastar.org/helicopters_eng/bell_222.php [3 ] URL-3 http://www.flugzeuginfo.net/acdata_php/acdata_222_en.php

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ISTANBUL TECHNICAL UNIVERSITY

FACULTY OF AERONAUTICS AND ASTRONAUTICS

Mehmet ERGNER B. Burak ZKAHYA Halil KUL SUMMER 2010

DESIGN OF MACHINE ELEMENTS GEAR WHEEL

TABLES AND FIGURES

Design Of Machine Elements | Asst. Prof. Dr. Halit S. Trkmen

Table 1 Lycoming LTS-101-650C-3

Motor Power Turn Reduction Ratio Motor Speed Rotor Speed

2 461 kW 21.91 9597 RPM 438 RPM

Design Of Machine Elements | Asst. Prof. Dr. Halit S. Trkmen

Figure-1 Bell 222

2) ANALYSIS OF GEAR MECHANISM

Design Of Machine Elements | Asst. Prof. Dr. Halit S. Trkmen

from table 2 from table 3 from table 4

According to fracture; dimension, mm

According to pitting; dimension, mm

From table 13-2 (Mechanical Engineering Design, It can be choose module,

For this V value, from table 1

From preferred size table,

Face Width: 2.1.2) Gear of the first step:

2.2) SECOND MECHANISM

According to pitting; dimension, mm

From table 13-2 (Mechanical Engineering Design, It can be choose module,

For this V value, from table 1 According to pitting; dimension, mm

3) FORCE AND MOMENT ANALYSIS OF THE SHAFTS

Design Of Machine Elements | Asst. Prof. Dr. Halit S. Trkmen

Length of the shaft,

3.1.1) Moment Diagrams:

Design Of Machine Elements | Asst. Prof. Dr. Halit S. Trkmen

Moment Diagram For The First Shaft

3.2) SECOND SHAFT

Length of the shaft,

For helical gear;

Design Of Machine Elements | Asst. Prof. Dr. Halit S. Trkmen

For bevel pinion;

Design Of Machine Elements | Asst. Prof. Dr. Halit S. Trkmen

Design Of Machine Elements | Asst. Prof. Dr. Halit S. Trkmen

3.2.1) Moment Diagrams:

Moment Diagram For The Second Shaft

Design Of Machine Elements | Asst. Prof. Dr. Halit S. Trkmen

3.3) THIRD SHAFT

Length of the shaft, Rotor Speed;

Design Of Machine Elements | Asst. Prof. Dr. Halit S. Trkmen

Design Of Machine Elements | Asst. Prof. Dr. Halit S. Trkmen

Moment Diagram For The Third Shaft

4) DIMENSIONAL ANALYSIS FOR THE SHAFTS

4.2) SECOND SHAFT

Design Of Machine Elements | Asst. Prof. Dr. Halit S. Trkmen

4.3) THIRD SHAFT

5) SELECTION OF THE BEARINGS

Design Of Machine Elements | Asst. Prof. Dr. Halit S. Trkmen

5.2) SECOND SHAFT

5.3) THIRD SHAFT

Design Of Machine Elements | Asst. Prof. Dr. Halit S. Trkmen

6) SELECTION OF THE KEYS

Yield Strength 550 MPa=79.8 kpsi Shear Strength

Design Of Machine Elements | Asst. Prof. Dr. Halit S. Trkmen

6.2) SECOND SHAFT

Yield Strength 550 MPa=79.8 kpsi Shear Strength

6.3) THIRD SHAFT

Yield Strength 550 MPa=79.8 kpsi Shear Strength

Design Of Machine Elements | Asst. Prof. Dr. Halit S. Trkmen