TIE-BAR WITH INTERNAL LUBRICATION

Abstract: The tie-bar (10) comprises a pair of spacedapart bushings (12, 14) each having end flanges (16) extending from a central cylindrical portion and a through opening (18) for connecting to flexing structures. A plurality of wires (20) comprising bands (22) of parallel wires (20) wrapped end­ lessly about the spaced-apart bushings (12, 14) provide a tie-bar (10) having bushings (12, 14) disposed at the ends and connected by a pair of spaced-apart side portions (24) of superimposed bands (22). The wires (20) are coated with a dry film lubricant so that the wires (20) are dry wrapped about the bushings (12, 14), and then a resin material (23) encapsulated about the dry wrapped wire bands (22) and bushings (12, 14). A body (26) of resin material disposed between the spaced-apart side portions (24) and the bushings (12, 14) maintains the spaced-apart relationship of the bushings (12, 14) by withstanding the compressive tension of the tightly wrapped wires (20). The wires (20) are free to move relative to one another in response to tension and torsional forces exerted upon the tie-bar (10).

Description: TIE-BAR WITH INTERNAL LUBRICATION The present invention relates to a tie-bar with internal lubrication between individual wire strands of the assembly whereby the wire strands are free to move relative to one another as a result of axial and torsional forces exerted thereon. It has been the practice to make structures subjected to high tensile and torsional loading, for example the connecting members or tie-bars between helicopter rotor blades and the driving rotor, from a pair of metal bushings connected together by endless stranas of parallel wires secured together by an adhesive resin such as urethane, with the resin disposed between each of the wires. Such urethane impregnated tie-bar assemblies are illustrated in U. S. Patents Nos. 3,434,899 and 3,460,628 issued to James A. Tankersley on March 25, 1969 and August 12, 1969, respectively, and both assigned to the same assignee as herein. Urethane impregnated tie-bar assemblies present a number of problens in their manufacture and use. The tie-bar is wet wrapped during the assembly process and the urethane material comprises a carcenogenic material which requires that workers wear protective clothing in an enclosed area because of the inherent dangers. During the wrapping procedure, the urethane material can set up in approximately fifteen minutes, such that the assembly process must be continuous and additional new amounts of urethane added when the urethane in thp applicator reservoir sets up and becomes too firm for further effective wrapping. This problem relates generally to the pot life of the urethane material during the wrapping procedure. The urethanes utilized comprise the castable type which is placed within a form and assumes the castea form of the material, and which results in a costly assembly operation. During use, the urethane matrix separating the wires prevents galling or rubbing abrasion between the wires as a result of sheer deflections between the wires during operational twist cycles of the associated rotor blade. However, the continuous axial and torsional forces exerted upon the tie-bar during the operational twist cycles eventually deteriorate the urethane material of the matrix such that the galling between the wires may occur, and eventual delamination occurs. This has deliterious affects upon the operational wear life of the tie-bar. During assembly, the portions of the urethane coated wire strands which are wrapped about the bushings occupy a smaller volume than do the portions of the wires disposed between the bushings. This is because the wires are wrapped tightly about the bushings such that there is a radially inward force exertea by the wires against the bushings to compress the laminations of wires and minimize the amount of urethane contained between the wires. In the areas between the bushings, ie., the parallel side portions of the laminations of wires, there is no radially inward force other than the parallel wires disposed adjacent one another and thus the urethane matrix causes an increase in thickness of the wire form cross-section in the region between the bushings and results in an increase in the envelope of the tie-bar. Prior tie-bars have a solid body of urethane disposed between the parallel side portions of the laminations, but this body of urethane contributes no useful function because the tie-bars use the urethane impregnated matrix to maintain tension effected by the wrapping procedure. Because of the above problems inherent with castable urethane impregnated tie-bar assemblies, it is desirable to provide a tension-torsion tie-bar assembly which may be assembled in the initial wrapping procedure without the use of any carcenogenic material. A tensiontorsion tie-bar produced by a dry wrap process should provide a plurality of superimposea bands of wires which will permit free movement of the wires relative to one another, without galling or abrasion between the wires during the operational twist cycles of the flexing structures attached to the tie-bar. It is desired that the wires provice for the free movement of each other relative to one another whereby uneven force stresses exerted at the bushings are dissipated to the areas of the wires in the region between the bushings. The present invention comprises a tension-torsion tie-bar assembly which includes a pair of bushings each slaving a cylindrical center portion within flanges extending therefrom, and a through opening therethrough. A plurality of superimposed banas comprising wire filaments each having a dry film lubricant thereon, are wrapped endlessly about the bushings such that the bushings are in spaced-apart relationship with parallel or side portions of the wires extending therebetween. A low modulous resin or elastomeric material is then disposed about the bushings and superimposed bands so that they are encapsulated, and the area between the side portions of the wires comprises a solid body of resin or elastomeric material maintaining the compressive tension exerted by the superimposed bands on the spaced-apart bushings. The invention is described in detail with reference to the arawings which illustrate: Figure 1 is an isometric view of the tension torsion tie-bar assembly of the present invention; Figure 2 is the cross sectional view taken along view line 2-2 of Figure 1; Figure 3 is a cross sectional view taken along view line 3-3 of Figure 1; and Figure 4 illustrates the performance that results for a prior tie-bar and tie-bars made in accordance with the present invention. The present invention comprises a tensiontorsion tie-bar that may be utilized as a connecting member between a helicopter rotor blade and the driving rotor, such as illustrated in Tankersley U. S. Patents Nos. 3,434,899 and 3,460,628, each patent being incorporated by reference herein. The urethane impregnated tie-bar assemblies provide an undesirable sheer bond effect because the urethane is disposed between each of the wires so that a urethane matrix encompasses the superimposed bands of wires. During the twist operational cycles, forces cause the wires to move relative to one another and this is resistta by the urethane material disposed between the individual wires. As a result, this produces the undesirable sheer bond effect which resists the movement of the wires relative to one another. In the areas where the wires are wrapped around the bushings, the wires at different radii are strained differently and because the urethane material secures the wires together, the urethane matrix does not permit dissipation of forces to the two side portions of the wires disposed in the region between the bushings. The urethane material of the prior art structures is necessary in order to keep the bushings in their spaced-apart relationship and main tain the compressive force exerted by the wrapped wires against the bushings. While the urethane material initially maintains the compressive tension exerted by the wire laminations between the bushings, the shear bonds eventually weaken which leans to eventual deterioration of the tie-bar assembly. The present invention comprises a tension-torsion tie-bar assembly designated generally by reference numeral 10 in Figures 1 - 3. The tie-bar assembly 10 comprises a pair of bushings 12 and 14 disposed in a spaced-apart relationship in the assembly. Each bushing 12, 14 includes end flanges 16 extending radially outwardly from cylindrical portions which include through openings 18 therein. The bushings 12, 14 are disposed in a fixture similar to the fixture illustrated and explained in the Tankersley U. S. Patent number 3,434,899, incorporated by reference herein. However, the assembly procedure for the tie-bar of the present invention is significantly different and provides for certain major advantages and reduction in costs, as will be explained hereinafter. Reterring to Figures 2 and 3, a plurality of filaments 20 comprising dry film lubricant coated wires are wrapped continuously in an endless connection disposed about the bushings lv and 14. The wires are coated with a dry film lubricant such as graphite, molybdenum disulfide, or any equivalent lubricant which may be coated onto the wires prior to the assembly procedure for the tension-torsion tie-bar. Alternatively, the dry film lubricant may be coated on the wires during the assembly Procedure. The wires 20 are fed into and through a wrapping machine or apparatus as previously disclosed in the cited patents, but with a major difference comprising that the wires are dry wrapped about the bushings 12 and 14. In other words, resin material such as the previously used carcenogenic urethanes are not utilized in the wrapping process. The bands of wires disposed in parallel relatiorship are wrapped continuously about the bushings which are maintained within a fixture attached to the wrapping apparatus. When the wrapping of the bands of parallel wires 20 has been completed, there is produced a plurality of superimposed bands 22 of wires, with the cut ends of the wires attached to either the subassembly or the fixture holding the subassembly. This subassembly comprising the bushings with the superimposea bands 22 wrapped thereabout which provide side portions 24, may be used at that time in an encapsulation procedure or may be stored for an indefinate period of time and used in the encapsulation procedure at a later time. The encapsulation procedure is effected in essentially the same manner as described in the cited Tankersley patents. A resin material 23 such as a reaction injected molded elastomeric urethane is injected within the fixture device and about the superimposed bands to provide a smooth outer contour which affords protection in handling the coupling, and providing a solid body 26 of resin material between spaced-apart side portions 24. Alternatively, the material 23 may be an elastomeric thermoplastic or thermosetting urethane. The resin coated tie-bar assembly is then subjected to a cure process so that the resin material is completely polymerized. The product comprises the tie-bar assembly 10 which appears as a smooth surfaced, solid body comprising spaced-apart busiiings 12 ana 14, spaced-apart side portions 24 each encapsulating the superimposed bands 22 therein, and the solid body of resin material 26 disposed between the side portions. Ti#e tie-bar assembly of the present invention presents substantial advantages in assembly procedures and manufacturing costs, and provides a superior product as comparea to prior urethane inpregnated tie-bar assemblies. Because the tie-bar assembly 10 is wrapped dry, there is no messy debris to clean up after the wrapping assembly, ana more importantly, t}xere carcenogenic material involved whereby protective clothing and d cially restricted wrapping ared artt not necessary tor tilL wrapping procedure. The wrapping procedure may proceed at a more schedulea pace, with less criticality as to the clme period of the wrapping procedure, because the dry film coated wire stranas are ary wrapped ana thus matrix pot life is not a factor in the wrapping procedure. The encapsulation procedure can be performed at any time after the wrapping procedure, there being no need to accomplish this immeuiatedy thereafter because, again, matrix pot life is not involved. A wider choice of materials may be utilized for the encapsulating procedure. In the prior constructions, the encapsulation generally required that the same type of resin as the matrix material be used. The prior resins usually fell in the category of the castable type rather than the easier to process and less expensive reaction injection molded urethanes. The reaction infected molded urethanes are not only cheaper, but also are noncarcenogenic. Tiie tie-bar assembly of the present invention provides a proauct that is superior to prior urethane impregnated tie-bar assemblies. Because the individual wires are not separated and bonded by a urethane matrix, tne wires are free to move relative to one another in order to more efficently dissipate the uneven stresses and forces exerted on the wires in the vicinity of the bushings which provide for attactinent of the tie-bar assembly to the stress flexing structures. The dry film lubricant comprising graphite, molybdenum disulfide, or any other suitable dry powder or material applied to the wire prior to assembly, separates the wires ana lubri- cates the interfaces so that stress concentrations are not built up in the areas adJacent the bushings. When axial and torsional forces are exerted on the bushings, tne laminations of wire stranas at the bushings receive these forces and evenly dissipate the stresses to the regions of the wires disposed between the bushings. It should be clearly understood that the low modulous material or noncarcenogenic urethane material used in the encapsulation process and providing solid body 26 between spaced-apart side portions 24, keeps the bushings in their spaced-apart relationship and maintains the compressive tension exerted by the wire strand laminations tightly wrapped around the bushings. Thus, central body portion 26 maintains bushings 12, 14 in their spaceaapart relationship and maintains the superimposed bands in parallel relationship without penetrating between the bands to form the urethane matrix provided in prior art assemblies. Because the urethane material does not penetrate into the parallel strands of superimposed bands, the bands are free to move relative to one another during operational twisting cycles. Additionally, the elimination of the urethane matrix enables the cross section of superimposed bands at the regions between the bushings to be substantally identical to the cross section of the same bands in the areas at the bushings. Thus, there is no variation in the thickness of the cross sections which would increase the tie-bar envelope, and which occurred in the prior constructions because of the urethane matrix. The precoated, dry film lubricated wires are free to move and the lubricant prevents galling or rubbing abrasion between the wires. Because of the higher compressive strength of the dry film lubricant, the lubricant will be more effective in preventing galling than did the urethane impregnated structures. Urethane has a compressive strength of approximately five Hectobars, while the dry film lubricant has a compressive strength of approximately three hundred forty-five Hectobars. The tension-torsion tie-bar of the present invention can withstand higher loads and is more durable than the urethane impregnated tie-bar constructions. Because the present invention does not require a urethane matrix between the wires, there are no undesirable sheer bonds provided and thus the tie-bars do not become limp and delaminated after limited usage because of the deterioration of the shear bonds. Also eliminated is the requirement that some urethane impregnated tie-bar constructions had to incorporate a nylon corset as a redundant feature to mitigate the effects of delamination which occurred after the sheer bonas eventually deteriorated. The solid film lubricant used in the present invention will allow unhampered sheer deflections between the wires. This was not true of the prior urethane impregnated tie-bar constructions which tended to bond the wires together and restrict movement of the wires relative to one another and thereby caused stress concentration. It has been found that the complex strain patterns in tie-bars requires that the wires be able to shift freely relative to each other in order to avoid stress concentrations. This is effectively accomplished by the tie-bar construction of the present invention. Tie-bars assembled in accordance with the present invention have demonstrated a strong fatigue performance that was superior to that exhibited by the prior urethane impreg nated tie-bar constructions. The tie-bars maintained their shape and torsional stiffness throughout testing and proviaed superior results. A performance comparison is shown in Figure 4. Figure 4 illustrates a performance test comparison between a wet-wrapped urethane impregnated tie-bar (A) and three tie-bars with internal lubrication (B, C, and D) and made in accordance with the present invention. Each tie-bar A-D was subjected to torsion (twisting) and tension (stretching) Figure 4 illustrates the superiority of tie-bars having internal lubrication. Although this invention has been described in connection with the illustrated embodiment, it will be obvious to those skilled in the art that various changes may be made in the form, structure, and arrangement of parts without departing from the invention.

Claims: CLAIMS 1. A tension-torsion tie-bar (10) comprising a pair of bushings (12, 14) having spaced radially extending flanges (16), means (18) for connecting each of said bushings (12, 14) respectively to structures exerting stress on the longitudinal axis of the tie-bar (10), a plurality of superimposed bands (22) including individual wires (20) disposed in adjacent, parallel arrangement, said wires (20) wrapped continuously around said bushings (12, 14) to form a solid link having semi-circular ends joined by oppositely disposed, spaced-apart side portions (24) of said superimposed bands (22), and an adhesive composition (23) disposed between said spaced-apart side portions (24) and encapsulating said side portions, characterized in that each of said wires (20) has a solid film lubricant thereon so that said wires may move relative to one another and adhesive composition (23) disposed between said side portions (24) forming means (26) for maintaining the bushings (12, 14) in spaced apart relationship. 2. The tie-bar (10) in accordance with claim 1, wherein said solid film lubricant comprises one of graphite and molybdenum sulfide. 3. The tie-bar (10) in accordance with claim 1, characterized in that the connecting means (18) comprises a through opening (18) in each of said bushings (12, 14). 4. The tie-bar (10) in accordance with claim 1, characterized in that said wires (20) are free to move relative to one another while substantially preventing abrasion by engagement therebetween. 5. The tie-bar (10) in accordance with claim 1, wherein said adhesive composition is chosen from the group consisting of a reaction injected molded elastomeric urethene, an elastomeric thermoplastic, and a thermosetting urethane. 6. A method for making an endless girding structure (10) of dry film lubricant coated filaments (20), comprising the steps of: drawing said dry film lubricant coated filaments (20) from uniformly rotating spools; drawing said filaments (20) through a die to arrange each of said filaments (20) parallel to each other in a band formation; attaching an end of the band formation (22) to one of two spaced-apart flanged bushings (12, 14) in a rotating fixture; rotating said fixture to wrap the band formations (22) about each of the bushings (12, 14) between the flanges thereof; cutting the band formation of filaments (20) when a sufficent number of layers thereof have been wrapped about said bushings (12, 14) to form a lamination of band formations; securing the loose end of said band formation (22) of filaments: and encapsulating the lamination of band formations (22) by application of an adhesive material (23) thereabout and curing to polymerize the material. 7. The method in accordance with claim 6, wherein noncoated filaments (20) are drawn from said spools and then coated with a solid film lubricant comprising one of graphite and molybdenum disulfite. 8. The method in accordance with claim 6, wherein said material (23) comprises a low modulous urethane. 9. The method in accordance with claim 6, wherein adhesive material (23) disposed between side portions (24) of the band formations (22) and bushings (12, 14) provides a body of material (23) for maintaining compressive tension between said bushings (12, 14). 10. The method in accordance with claim 9, wherein said adhesive material (23) disposed between said side portions (24) and bushings (12, 14) provides a solid body (26) of material maintaining the side portions (24) of band formations (22) in parallel relationship to one another. 11. The method in accordance with claim 6, wherein said adhesive material (23) is chosen from a group consisting of a reaction injected molded elastomeric urethene, an elastomeric thermoplastic, and a thermosetting urethane. 12. The method in accordance with claim 6, wherein said dry film lubricant is chosen from a group consisting of graphite and molybdenum disulfite.

Inventors: DITLINGER, RICHARD J. ALLIED CORPORATION
Applicants: ALLIED-SIGNAL INC.
Application year: 1985
Main classification: F16C7
IPC codes: F16C7, B29C53