Development of a Coupled Torsional Dynamics and Gear Contact Model to Predict Peak Loads in a Tiltrotor Drive System

Abstract

The tiltrotor drive system is a complex and coupled system with different torsional dynamics compared to conventional rotorcraft. It is designed to guarantee safety and reliability and tested for the effects of its dynamics and loads on component sizing. The epicyclic gearing system, the final reduction stage in most aircraft gearboxes, is most impacted by such dynamics. The components of this subsystem must withstand all peak loads due to novel control strategies and torsional dynamics. In this paper, a gear contact analysis model is coupled with a validated torsional dynamics model of a tiltrotor interconnected drive system. The coupled model predicts component-level design loads in the interconnected drive system originating from its torsional dynamic behavior. An accurate gear macro and micro geometry is generated in the gear contact model which is used to derive the time varying mesh stiffnesses at the sub-component interfaces. The variable mesh stiffnesses are applied in the gear dynamic model to simulate the dynamic responses of the gear system under load. Finally, a dynamic overload factor relating the peak dynamic and static loads is analytically assessed, and it is shown to exceed conventional predictions in the case of an asymmetrically loaded interconnected drive system. This dynamic factor can be implemented to inform design decisions during the development of future multi-rotor VTOL aircrafts to mitigate component damage and, in turn, increase the safety and extend the lifespan of critical components.