High Power Density Gears Using a Systems Engineering Approach for Selection, Test, and Evaluations of Emerging Materials, Surface Engineering, and Tri

Comprehensive tribology tests methods developed for aeropropulsion are proposed to provide a reliable and efficient means to evaluate emerging technologies for high power density gears. The tribology test methods include scuffing load capacity, Performance Mapping for wear and scuffing, surface initiated fatigue (micro-pitting) and oil-out performance. All these methods are scientifically based on tribology theory with a contact system composed of four structural elements representing technologies for surface durability. Five key tribology parameters are used to link micro-scale tribology mechanisms with engineering scale operating conditions. Tribology test machines (WAM) are based on these parameters as well as test methodologies. Phase I demonstrates the utilization of these test methods to define the performance limits of current state-of-art gear and lubrication technology (AISI 9310 gear steel and DOD-PRF-85734 gearbox oil). These performance limits are to be compared with a set of enhanced gear and lubrication technologies to demonstrate and quantify enhanced power density performance. An innovative concept is proposed for “tribologically tuned teeth” to balance and distribute wear/scuffing attributes across the active tooth profile with micro-pitting attributes. An advanced test machine concept is proposed to satisfy the need for improved high cycle micro-pitting tests.