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S92 Gearbox OptimizationHyperWorks Technology Conference 2010
Bruce Hansen Sikorsky Aircraft
Philip Kosarek Altair ProductDesign
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H-60 BlackHawk Transmission System
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S-76 Transmission System
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S-92 Gearbox Optimization
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Project Overview
S-92 Gearbox Optimization Objective
Substitute Aluminum for Magnesium in the S-92 gearbox with theoverall goal a weight neutral change. This investigation is to address
marine air corrosion and frequent maintenance intervals for the currentMagnesium design on production aircraft.
2-Phase Optimization Approach
The first phase was considered a Proof-of-Concept phase, and theproblem statement was kept simple. Optimization was conducted toenhance the stress performance of the housing without furtherincreasing the weight of the baseline Aluminum design.
The second phase was to design a minimum-weight aluminum housing
with fatigue performance that is better or equivalent to that of thebaseline Magnesium design. In order to keep optimization simple, the
ratio of max/yield was used as a basic measure of fatigue. The secondphase is documented in this presentation though both phases follow asimilar approach.
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Project Overview (cont.)
Optimization Methodology
FE Model Setup Loadcase Details
Baseline Results Topology Optimization Design Interpretation Free Shape Optimization
Final Design
Analytical Model Solver Details
Baseline Analysis & Design Validation
Nonlinear analysis including contacts employing 2nd order elements(C3D10M) using ABAQUS
Optimization Linear analysis employing 1st order elements using OPTISTRUCT
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Frame fixed aroundthe perimeter
4 attachments ofmiddle housing tothe frame
6 attachments ofmiddle housing tothe input housing
6 attachments of
middle housing tothe output housing
Frame material:
Aluminum A357
Housing material:
Magnesium AZ91E
Aluminum A357
Output Gear Box
Input
Gear Box MiddleGear Box
FE Model Setup
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Bearing loads
Input Housing Output Housing
Loadcase Details
Radial and axial bearing loads (suppliedby Sikorsky) applied in a local cylindricalcoordinate system.
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Magnesium Aluminum
Baseline Results
Input Housing
Middle Housing
Output Housing
Input Housing
Middle Housing
Output Housing
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Objective: Minimize strain energy of the Aluminum gear box assembly
Constraint: Total mass of the three Aluminum gear boxes 18.9 lb
Design Space Non-design Space
Input Housing Middle Housing Output HousingBaseline MG: 3.9 lb Baseline MG: 7.6 lb Baseline MG: 7.3 lb
Baseline AL: 5.9 lb Baseline AL: 11.5 lb Baseline AL: 10.9 lb
Topology Optimization
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Topology Optimization Results
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ReduceFlangeThickness
Interpreted Design AL (4.682 lb)
ReduceWallThickness
Scallop Flange
ReduceRibThickness
Baseline Interpreted Design
AddPocket
Input Housing:
Baseline MG: 3.951 lbBaseline AL: 5.927 lb
Int. Design AL: 4.682 lb
Topology Load Path(Conceptual Design)
Design Interpretation
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Interpreted Design AL
(5.526 lb)
ReduceWallThickness
Add Pocket
Trim / RemoveRibs
ReduceWallThickness
Baseline Interpreted Design
Topology Load Path
(Conceptual Design)
Output Housing:Baseline MG: 7.269 lb
Baseline AL: 10.903 lbInt. Design AL: 5.526 lb
Design Interpretation (cont.)
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Interpreted Design Evaluation
Input Housing Output HousingMiddle Housing
Generate FEA models of the interpreted design andevaluate radial and axial bearing loadcase.
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Design Space
Similar free shapeoptimization wasperformed on these areas
Objective: Minimize strain energy of theAluminum gear box assembly (input housing,center housing, and output housing).
Constraint: Scaled local stress ratio 0.8
Design Space
Free Shape Optimization
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Baseline Design
Interpreted Design
Final Design
Middle Housing:
Baseline MG:7.671 lbBaseline AL:11.508 lbInt. Design AL: 8.512 lb
Final Design AL: 8.532 lb
Final Design
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Output Housing:
Baseline MG: 7.269 lbBaseline AL: 10.903 lbInt. Design AL: 5.526 lbFinal Design AL: 6.257 lb
Baseline Design Final DesignInterpreted Design
Final Design (cont.)
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InterpretedDesign
Final Design
Final Design (cont.)
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max : Maximum Von Mises Stress (elements attached to rigids excluded)yield : Yield stress
* In order to have a balance between weight reduction and performance, the finaldesign of the output housing was targeted to a similar stress ratio as the inputand middle housings.
Results Summary
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S-92 Gearbox Optimization
31% reduction in mass over directly substituting aluminum into
the existing design. Increased durability, reduced maintenance and downtime
Savings in design cycle times
Typical manual optimization process ~ 6 months
S-92 Gearbox Optimization ~ 1 month Method viable for wide range of helicopter systems
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