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This work has been carried out in cooperation with The Construction Office of WSK “PZL-KALISZ” S.A.” and is part of Grant Agreement No. POIR.01.02.00-00-0002/15 financed by the Polish National Center for Research and Development.
The paper presents a case study of the failure of components of a reciprocating Diesel engine that
is planned for use in the aviation sector. The PZL-100 engine is being developed in cooperation
with company WSK PZL Kalisz. The object of the study was the gear used to transmit the engine’s
drive. The gears are designed to transmit moments from the two crank-piston shafts to the pro-
peller shaft used to propel the aircraft. The damage to the gears occurred as a result of operating
the engine under stationary conditions during brake testing. Visual inspection of the engine
revealed traces of gear seizure on the propeller shaft. In order to analyse the resulting fault and
prevent it from occurring in the future, simulation studies were performed using the finite
element method FEM in Catia v5 software. For this purpose, the geometric model of the propeller
shaft gear was reflected. The material properties and the appropriate density of the calculation
grid were selected. Boundary conditions, i.e. part restraint and force conditions (obtained from
previous calculations in MSC Adams software) were applied to the model thus prepared. Due to
the damage that occurred, it was decided to perform calculations in two variants: during normal
gear operation and during the conditions that caused the damage, i.e. the extreme case of locking
the wheel hub on the propeller shaft. The results of the simulation studies were presented in the
form of stress maps on the outer surfaces of the gear. The maximum stress values were obtained
on the gear shoulders at the hub, i.e. where the shoulders cracked. The simulation studies con-
ducted made it possible to identify and confirm the problem occurring during the operation of the
drive unit. As a result, it was proposed to change the geometry of the gears by strengthening their
shoulders
