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AGMA 05FTM13:2005 Edition

AGMA 05FTM13:2005 Edition

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Evaluation of the Scuffing Resistance of Isotropic Superfinished Precision Gears

Published By Publication Date Number of Pages
AGMA 2005 12
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Authors: Paul W. Niskanen, Alion Science and Technology, Bruce Hansen, Sikorsky Aircraft

Corporation and Lane Winkelmann, REM Chemicals, Inc.

The high performance required from aerospace gears places stringent requirements upon the metallurgical

quality, geometry, and surface finish of mating parts. In an effort to meet their mission requirements,

2005 FTM 5

aerospace gears are often engineered to operate near the upper bounds of their theoretical design

allowables. Due to this, scuffing is a primary failure mode for aerospace gears.

It was previously shown that specimens having an isotropic superfinish using chemically accelerated

vibratory finishing had an improved performance inRolling/Sliding Contact Fatigue (R/SCF) testing. Isotropic

superfinishing improved R/SCF resistance up to nine times that of baseline test specimens. These tests also

demonstrated the ability to successfully carry 30 percent higher loads for at least three times the life of the

baseline samples.

A study was then conducted on actual gears having an isotropic superfinish. This study showed isotropic

superfinishing technology increased a gear's resistance to contact fatigue by a factor of three, and increased

bending fatigue resistance by at least 10 percent. This increase in gear performance translates to reduced

operation and sustainment costs, and also offers the potential for weight reduction in new transmission

designs.

The present paper will discuss an additional study which is underway to determine and compare the scuffing

resistance of isotropic superfinished aerospace gears to that of baseline ground gears. Sample gears were

made from case carburized SAE 9310. These tests were conducted using a method that progressively

increases lubricant temperature until scuffing occurs, rather than the traditional load increasingmethod used

in FZG testing rigs. The results of the current testing reveals that isotropic superfinished SAE 9310

specimens show at least a 40 F higher lubricant temperature at the point of scuffing compared to as–ground

baseline gears. Based on these results and the previous studies, it was concluded that this isotropic

superfinishing technology should be incorporated in all future aerospace gear designs. A later paper will

report on similar scuffing testing performed onAMS 6308 gears due to run–outs achieved by both the baseline

and isotropic superfinished samples during the current procedure.

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