Composite Hybrid Gear Assembly for Triaxial Load Resistance
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Solution Overview
Problem
Current hybrid gear systems, particularly those with complex geometries like bevel gears, face challenges in withstanding triaxial loading due to their complex geometry, which existing composite designs and manufacturing methods struggle to address effectively, leading to weight and efficiency issues in applications like rotorcraft and aircraft transmissions.
Innovation Solution
A composite hybrid gear assembly is developed, featuring a gear hub formed from composite materials integrated with metallic components, including a shaft region with an axially symmetrical profile and a flared hub web, along with a gear head assembly and sleeves, where adhesive is applied to metallic surfaces and a preform is constructed and infused with resin to form a lightweight yet mechanically robust gear assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If all metal gear systems are used to ensure strength and durability, then mechanical integrity is maintained, but weight increases significantly
Solution Approach 1:
The patent applies composite materials by integrating a metallic gear head assembly with a composite material gear hub. The gear hub is formed using dry fiber preform infusion with resin, creating a hybrid structure that combines the high strength of metal with the lightweight properties of composite materials. This resolves the contradiction by maintaining mechanical integrity through the metal gear teeth and head while reducing overall weight through the composite hub structure.
2Weight of moving object
If composite materials are used to reduce weight, then gear assembly weight decreases, but ability to withstand triaxial loading in complex geometries deteriorates
Solution Approach 1:
The patent segments the gear assembly into two distinct parts: a metallic gear head assembly that withstands triaxial loading and complex stresses, and a composite material gear hub that provides lightweight structural support. The gear head assembly includes the gear teeth and head web, which are subjected to complex loading, while the hub serves as a lighter-weight mounting structure. This segmentation allows each component to be optimized for its specific functional requirements.
3Ease of manufacture
If layered prepreg application is used for flat web profiles, then manufacturing is simplified, but complex bevel gear geometry cannot be achieved
Solution Approach 1:
The patent changes the manufacturing parameter from layered prepreg application to dry fiber preform infusion. This parameter change enables the fabrication of complex three-dimensional bevel gear geometries with flared hub web profiles and angled tooth surfaces that cannot be achieved through conventional layered composite techniques. The infusion process allows resin to penetrate and saturate the dry fiber structure, curing into complex shapes while maintaining structural integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the creation of lightweight gear assemblies capable of handling triaxial loading, reducing weight and vibration while maintaining mechanical integrity, thus enhancing the efficiency and speed of aircraft and rotorcraft systems.
Implementation Method 1
applying adhesive to a gear head assembly at the regions of contact between a gear hub and the gear head assembly
Implementation Method 2
infusing uncured resin into the preform
Implementation Method 3
curing the preform to harden the adhesive and the uncured resin in the preform
Data Source
AI summary
A composite hybrid gear assembly includes a gear hub formed from a composite material and a gear head assembly. The gear hub includes a shaft region having an axially symmetrical external profile and a hub web region having a flared profile extending from the shaft region. The gear head assembly includes a head web region and a teeth region where the gear head assembly is fixed to the gear hub. Additionally, the composite hybrid gear assembly includes a first sleeve fixed to an external surface of the shaft region. An associated method of making a composite hybrid gear assembly is also provided.