The authors have developed the analytical geometry of face-gear drives, proposed the method for localization of bearing contact, developed computerized simulation of meshing and bearing contact, investigated the influence of gear misalignment on the shift of bearing contact and transmission errors. Application for design is discussed. The obtained results are illustrated with numerical examples.

The use of face-gears in helicopter transmissions was explored. A light-weight, split torque transmission design utilizing face-gears was described. Face-gear design is discussed. Topics included basic design geometry, tooth generation, limiting inner and outer radii, and recommendation for the gear ratio. Face-gear experimental studies were also included and the feasibility of face-gears in high-speed, high-load applications such as helicopter transmissions was demonstrated. Torque-split tests were performed and demonstrated an accurate split of torque using the face-gear concept.

The use of face gears in helicopter transmissions was explored. A light-weight, split torque transmission design utilizing face gears was described. Face-gear design and geometry were investigated. Topics included tooth generation, limiting inner and outer radii, tooth contact analysis, contact ratio, gear eccentricity, and structural stiffness. Design charts were developed to determine minimum and maximum face-gear inner and outer radii. Analytical study of transmission error showed face-gear drives were relatively insensitive to gear misalignment, but tooth contact was affected by misalignment. A method of localizing bearing contact to compensate for misalignment was explored. The proper choice of shaft support stiffness enabled good load sharing in the split torque transmission design. Face-gear experimental studies were also included and the feasibility of face gears in high-speed, high-load applications such as helicopter transmissions was demonstrated.

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An experimental programme to test the feasibility of using face gears in a high-speed and high-power environment was conducted. Four face gear sets were tested, two sets at a time, in a closed-loop test stand at pinion rotational speeds to 19 100 r/min and to 271 kW (364 b.h.p.). The test gear sets were one-half scale of the helicopter design gear set. Testing the gears at one-eighth power, the test gear set had slightly increased bending and compressive stresses when compared to the full-scale design. The tests were performed in the NASA Lewis spiral bevel gear test facility. All four sets of gears successfully ran at 100 per cent of design torque and speed for 30 million pinion cycles, and two sets successfully ran at 200 per cent of torque for an additional 30 million pinion cycles. The results, although limited, demonstrated the feasibility of using face gears for high-speed, high-load applications.