Scalable Integrated Hybrid Gear/Shaft

In support of the Future Vertical Lift Program (FVL), the Army is seeking to reduce weight, vibration, and noise on new helicopter design. Past research has explored making hybrid bull gears in order to reduce weight and noise of helicopter transmission systems. Cornerstone Research Group (CRG) proposes to push this research further by designing and making intermediate gearbox hybrid bevel gears using resin transfer molding (RTM). These gears will maintain steel teeth, but utilize composite materials for the gear web and gear hub. The product will decrease transmission weight and vibration, while costing less and having better quality compared to other hybrid gear manufacturing processes. In Phase I, CRG will develop scalable hybrid bevel gear designs and fabrication procedures, culminating with scaled demo parts. Phase II efforts will build on Phase I’s work to optimize gear design and procedures, and will culminate with two prototype gears that will be sent to the Army to test against flight qualification standards. Phase III will focus on transitioning the technology for Army use within rotorcraft and commercialization of hybrid bevel gear technology for other markets.