J. Garhart, Sikorsky Aircraft, Seymour, CT
An overview of the development and qualification of a carbon fiber composite drive shaft system is presented as a summary of the design approach, material characterization and article test. As part of the UH-60M upgrade program, weight reductions have been achieved through the implementation of composite materials for airframe and dynamic systems applications. The introduction of an all composite tailcone precipitated the requirement for a compatible composite tail rotor drive shaft to provide a suitably matched coefficient of thermal expansion. Improvements in manufacturing technology in recent years have enabled the expansion of composite laminates into the domain of dynamic components with critical load and precision balance requirements. This effort utilized proven manufacturing methods to produce a composite structure with highly controlled properties to successfully replace the legacy metallic component. Triaxial braid architecture was selected as the structural reinforcement for the design to address the components physical, mechanical and ballistic requirements. Resin transfer molding was chosen as the manufacturing method using CYCOM 890 resin to the meet stringent dimensional tolerances of a dynamic component. Component qualification testing was conducted to ensure that the dynamic response, mechanical properties and ballistic tolerance of the shaft met the existing system requirements. This research was partially funded by Army ManTech under contract No. DAAH23-2-C-R002. The U.S. Government is authorized to reproduce and distribute reprints for Government purposes notwithstanding any copyright notation herein. The views and conclusions contained in this document are those of the authors and should not be interpreted as representing the official policies, either expressed or implied of the Army ManTech office or the U.S. Government.
Summary: This presentation provides an overview of the development and qualification of a tail rotor drive shaft for the UH-60M aircraft using a building block approach to produce required data in parallel with design maturation and analysis. This program included mechanical coupon and sub-element risk reduction testing to develop material allowables, fatigue data and ballistic performance to serve as the basis of the structural substantiation of the design.
