ME314 Fall 2016 Group Design Project

Conceptual Flap Transmission Design

Objective:
A drive transmission is to be designed for the Leading Edge Flap Drive Mechanism (LEFDM) of a tactical
aircraft. The transmission attaches the leading edge flap to the wing front spar and provides actuation of the
flap. The flap is attached to the transmission by a set of lugs that are integrally machined into the flap spar
and the transmission is attached to the wing by a set of lugs that are also integrally machined into the wing
spar. The transmission is driven by a torque shaft that receives power from a hydraulic drive unit.
The transmission converts high speed, low-torque input into low speed, high-torque output for flap position
control. The transmission shall provide a maximum upper deflection of 12 and a maximum lower deflection
of 33, measured from the reference plane. The HDU delivers a maximum torque of 87 ft-lb at a speed of
3500 rpm. The flap structural weight is 209 lb, and is subject to an upward air load of 115-lb applied to the
centroid as shown. The flap deflection rate is 18/sec with load.
The input shaft speed is 400 rpm with an input torque of 230 5 in-lb and the output torque of 125000
3000 in-lb
The LEFDM shall meet the specified package dimensions and shall weigh no more than 15 lb.

UP

FWD FWD

OUTBD
12

INBD IDLER
HINGE LINE
18/sec 33

7.85 in

OUTBD IDLER
HINGE LINE

TORQUE SHAFT

WING BOX
FLAP HINGE LINE

LEADING EDGE
FLAP

The transmission is required to have a service life of 7,000 hours, after which the cost of any potential
upgrades/improvements will no longer result in any benefit.
 Structural Considerations:
The transmission connects the flap assembly to the wing through a of eight lug sets that are integrally
machined into the wing and flap spars. The lugs are aluminum with press-fit BeCu bushings installed, and the
transmission is installed using a 0.6635 0.0015 inch diameter steel pin. The allowable gap between the
transmission drive lugs and the mating spar and flap lugs is 0.038 0.005 in.
The geometry of the mating wing spar transmission lugs is shown in the figure below:
0.910
0.010
0.323
2.550
0.008 0.323 12.166
0.005
0.008 0.003
FWD
8.826
0.003 OUTBD
5.486
0.003

3.229 2.146
0.005 0.003
0.75R
0.440 0.368
UP 0.008 0.008

1.498 FWD
0.005

1 2 3 4 5 6 7 8

2.820 FOR LUGSETS 6.285

0.010 2/3 4/5 6/7 0.003
3.830
0.010
VIEW LOOKING DOWN ON WING SPAR

The geometry of the mating flap transmission lugs is shown in the figure below:
0.670
0.295 0.005
0.008
2.511 0.295 FWD
0.005 0.008
5.345 OUTBD
0.005

3.109 2.00R 1 2 3 4 5 6 7 8
0.005

UP

1.524 FWD
3.340
0.005
0.005

6.680
0.005
10.020
0.005
2.800
0.005 VIEW LOOKING DOWN ON FLAP SPAR
3.960
0.010
Loads Considerations:
The mating spar and flap transmission lugs have been sized for the applied aerodynamic and inertial loads.
The ultimate loads (reactions) imposed on the transmission at the mating spar and flap lugs are listed in Table
1 and 2.

Table 1: Ultimate Load Summary Lower Lugs

Lug # 1 2 3 4 5 6 7 8
Flap Side Py 15219 14979 13730 13426 13570 13563 13180 14468
Pz 18959 16698 16867 15249 15698 17156 17137 24951
Wing Side Py 13711 16242 17128 16749 16929 16920 16442 19454
Pz 19523 17490 21042 19024 19584 21402 21379 31126

Table 2: Ultimate Load Summary Upper Lugs

Lug # 1 2 3 4 5 6 7 8
Flap Side Py 7813 7727 6921 6811 6679 6677 6092 6755
Pz 10022 8212 8281 7681 7702 7908 7862 11786
Wing Side Py 11015 10894 9758 9603 9416 9414 8589 9523
Pz 14129 11578 11675 10828 10858 11149 11084 16616

The transmission installation layout is shown below.

FWD

OUTBD Py FWD
FLAP SIDE
Pz
UP

TRANSMISSION
UNIT

FLAP HINGE LINE

WING SIDE
Required:
Propose a workable design concept that will satisfy the stated requirements. At this stage, the goal is a
workable design that is structurally viable; further development will take place once the design concept has
been confirmed.
Prepare a schematic layout of the proposed design concept.
Design/size the LEFDM mating lugs:
Material selection for the transmission pins and lug sets
Dimensioning/tolerancing of lug sets
Stress analysis of lugsets
Apply a minimum design factor of nd = 1.5 for the lugs
Prepare a written report summarizing the design requirements and your proposed design concept to meet these
requirements. Describe how your proposed design will meet or exceed the problem requirements. You are to
work in teams of up to 8 students; only one report is required per team. Report is to be typed and illustrations
prepared using a graphics program.