Static Torsion Testing and Modeling of a Variable Thickness Hybrid Composite Bull Gear

Torsional strength of a variable thickness hybrid gear web was measured by performing static testing on the part in a large torsion test frame. The outer rim of the hybrid gear web was fixed to the bottom of the test frame and loading was applied to the web through a shaft. The test setup included the installation of digital image correlation (DIC) systems to obtain deformation and strain measurements from the surfaces of the hybrid gear web and the mechanical test equipment to ensure reliability of the test. The results indicated that the variable thickness hybrid gear web achieved approximately twice the torsional strength compared to that of previous hybrid gear designs. The DIC analysis showed significantly more straining of the loading shaft than the actual test article. Additionally, the results demonstrated the importance and affect that the metallic, lobed interlock features had on the principal strain and out-of-plane displacement fields. The analysis revealed that the fixed outer rim was in fact rotating and a rigid body motion compensation (RBMC) function was computed to determine the actual rotation of the hub and composite web relative to the outer rim. Modeling simulations were performed for the variable thickness hybrid gear web and correlated well with the RBMC rotational deformation seen in the DIC analysis. In addition to benchmarking the load capacity of the hybrid gear web, measuring its strength is useful information to define the parameters needed for dynamic, endurance, and other testing of the part.