This paper summarizes the development and implementation of material-based prognostic technology for modeling fatigue damage in rotorcraft drive system rotating components considering manufacturing process, contact pattern, lubrication effects, stresses, microstructure, and material variability. The AMS 6265 and AMS 6308 prognostic models were developed and applied to predict contact and bending fatigue damage in the planetary gear system. Prognostic model was verified by comparing fatigue life simulation results with industry test data. Prognostic model results were demonstrated and designed for integration with onboard and offboard elements of industry health monitoring/management systems. This paper includes details on predicting contact fatigue and bending fatigue life, endurance limits, maximum continuous power (MCP) rating, and overload effects. Prognostic model results show the application of this gear health algorithm solution in rotorcraft drive system transmission gear design, inspection, maintenance, and recommendation of safe operational powers.
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