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Abstract:The trochoidal-gear technology has been growing in groundbreaking fields. Forthcoming applications are demanding to this technology a step forward in the conceiving stage of positive displacement machines. The compendium of the qualities and the inherent characteristics of trochoidal-gear technology, especially towards the gerotor pump, together with scale/size factor and magnetic-driven transmission has led to the idea of a magnet-sleeve-sealed variable flow mini trochoidal-gear pump. From its original concept, to the last phase of the design development, the proof of concept, this new product will intend to overcome problems such as noise, vibration, maintenance, materials, and dimensions. The paper aims to show the technological path followed from the concept, design, and model, to the manufacture of the first prototype, where the theoretical and numerical approaches are not always directly reflected in the prototype performance results. Early in the design process, from a standard-commercial sintered metal mini trochoidal-gear unit, fundamental characteristics and dimensional limitations have been evaluated becoming the strategic parameters that led to its configuration. The main technical challenge to confront is being sealed with non-exterior driveshaft, ensuring that the whole interior is filled and wetted with working fluid and helping the hydrodynamic film formation, the pumping effect, and the heat dissipation. Subsequently, the mini pump architecture, embodiment, methodology, materials, and manufacture are presented. The trend of applications of polymer composite materials and their benefits wanted to be examined with this new mini pump prototype, and a pure polyoxymethylene mini trochoidal-gear set has been designed and manufactured. Finally, both the sintered and the polymer trochoidal-gear units have been experimentally tested in an in-house full-instrumented mini test bench. Although the main goal of the presented work is the development of a new mini trochoidal-gear pump prototype rather than a numerical study, the results have been compared with numerical simulation. Subsequently, the prototype of the mini trochoidal-gear pump is a feasible proof of concept supported by functional indexes and the experimental results.

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Paper presents the construction and results of experimental research of gerotor pump with gears made of POM and PPS. Research program included verification of design factors (axial and radial clearance), operational factors (impact of speed, pressure and temperature on the pump characteristics) and definition of durability characteristics. Results of research proves that the pump with gears made of plastics can operate at high speeds (up to 4000 rpm), at temperature of the working fluid in the range 25°C – 50°C, with the working pressure at the outlet of the pump 4 MPa. Presented results of long-term tests, shows that the pump with gears made of plastics worked for 40 hours maintaining a constant level of efficiency Q = 12.5 dm3, which represents 80% of the theoretical volumetric efficiency.

The article presents a comparison of the hole-flange factors for four steel sheets which have different strength parameters. Three types of punches were applied in the research: cylindrical, spherical and conical. The holes in the samples were made with the use of the following cutting technologies: laser cutting, electrodischarge method using wire and punching. The coefficient of the hole expansion shows that the shape of the used tools has a great impact on the final diameter of the hole. The greatest enlargement of the diameter was obtained for the conical punch, a smaller enlargement for the spherical one and the smallest enlargement for the cylindrical punch. The results of the hole expansion tests using the conical punch diverge from the general rule saying that the greater the plastic deformation of the sheet metal during tensile tests, the more you can enlarge the hole before cracking appears.

This article is devoted to the issues of thermal softening of materials in the surface layer of forging tools. The research covers numerical modeling of the forging process, laboratory tests of tempering of nitrided layers, and the analysis of tempering of the surface layer of tools in the actual forging process. Numerical modeling was supported by measuring the temperature inside the tools with a thermocouple inserted into the tool to measure the temperature as close to the surface as possible. The modeling results confirmed the possibility of tempering the die material. The results of laboratory tests made it possible to determine the influence of temperature on tempering at different surface layer depths. Numerical analysis and measurement of surface layer microhardness of tools revealed the destructive effect of temperature during forging on the tempering of the nitrided layer and on the material layers located deeper below the nitrided layer. The results have shown that in the hot forging processes carried out in accordance with the adopted technology, the surface layer of working tools is overheated locally to a temperature above 600 °C and tempering occurs. Moreover, overheating effects are visible, because the surface layer is tempered to a depth of 0.3 mm. Finally, such tempering processes lead to a decrease in the die hardness, which causes accelerated wear because of the abrasion and plastic deformation. The nitriding does not protect against the tempering phenomenon, but only delays the material softening process, because tempering occurs in the nitrided layer and in the layers deeper under the nitrided layer. Below the nitrided layer, tempering occurs relatively quickly and a soft layer is formed with a hardness below 400 HV.

Gearing is one of the most important rolling nodes in a cycloidal planetary transmission. It consists of gears whose outlines are created according to cycloidal curves and the rollers cooperating with them. The epicycloidal and hypocycloidal gearing can be distinguished. There are power losses during the transmission operation, due to the transmitted load and friction in the gearing. The paper presents an analytical method for determining losses in cycloidal gearing, taking into account the manufacturing deviations of the elements making this gearing. The analysis allowed determining the distribution of intertooth clearances and forces at the points of contact between the profiles and the rollers, and consequently the distribution of power losses in gearing. The distribution of intertooth forces was verified by elastooptic tests of the gears set with cycloidal gearing. The results of the calculations indicate that the influence of eccentricity changes on the distribution of intertooth forces is significant and also that the distribution of power losses in gearing is closely related to the distribution of intertooth forces and has a very similar character.