Fatigue Crack Initiation Prediction Tool for Rotorcraft Spiral Bevel Gears

Award Information
Agency:
Department of Defense
Branch
Army
Amount:
$69,860.00
Award Year:
2010
Program:
SBIR
Phase:
Phase I
Contract:
W911W6-11-C-0025
Agency Tracking Number:
A103-169-0326
Solicitation Year:
n/a
Solicitation Topic Code:
ARMY 10-169
Solicitation Number:
n/a
Small Business Information
Sentient Corporation
850 Energy Drive, Suite 307, Idaho Falls, ID, 83401
Hubzone Owned:
N
Minority Owned:
N
Woman Owned:
N
Duns:
089822014
Principal Investigator:
Raja Pulikollu
Lead Scientist
(937) 241-1144
rpulikollu@sentientscience.com
Business Contact:
Kris D'Antoni
Contracts Administrator
(208) 522-8556
kdantoni@sentientscience.com
Research Institution:
n/a
Abstract
Current life prediction methods, such as AGMA, are empirical-based, deterministic in nature and cannot consider the effects of gear manufacturing processes, material microstructure and lubrication on fatigue strength. The estimated life is as good as the information entered by the user and it requires considerable design, manufacturing and field experience. In addition, current methods cannot take into account the influence of surface finish and residual stress profile (due to shot peening) on gear life. This leads to excessive overdesigns and conservative life predictions. In this program, Sentient will develop probabilistic fatigue crack initiation prediction tool using finite element method (FEM), mixed-elastohydrodynamic lubrication (EHL) model, microstructure model, and probabilistic physics-based fatigue damage method. FEM and mixed-EHL methods will be used to estimate contact pattern and true stresses in spiral bevel gear. The microstructure model along with fatigue damage model will be used to predict time to crack initiation. When complete, the life prediction tool can be used to predict the influence of variation in manufacturing processes (carburization, shot peening), and material macro and microstructural properties on gear fatigue life.

* information listed above is at the time of submission.

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