A review on failure characteristics of polymeric gears

Jain, Mohit; Patil, Santosh; Ghosh, S. S.

doi:10.1063/1.5123979

Cited by 11 publications

(4 citation statements)

References 60 publications

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“…18), while the second one incorporated the maximum absolute values of the wear depth in addition to the integral (Eq. 19). Unless specified otherwise, the second objective function was employed for the optimization processes as it yielded slightly improved and notably smoother wear depth distributions.…”

Section: Case Study #1mentioning

confidence: 99%

“…This capability allows engineers and designers to optimize gear designs for specific applications, resulting in improved performance, reduced weight, and enhanced functionality [18]. Versatility and design freedom provided by 3D printing technology are predominant advantages of plastic gears, along with lightweight construction, self-lubrication and reduced manufacturing costs [19]. However, alongside the advantages of plastic 3D printed gears, wear emerges as a major concern [20].…”

Section: Introductionmentioning

confidence: 99%

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Improving the wear resistance of 3D printed spur gears through a free-form tooth flank optimization process

Kalligeros,

Papalexis,

Georgiou

et al. 2023

MATEC Web Conf.

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Involute gears have traditionally been the preferred choice for gear transmission systems due to their simplicity and interchangeability. However, there are applications where they do not provide the most durable and efficient solution. While the cost of implementing optimized non-involute gears in most applications often outweighs their comparative advantages, the advent of additive manufacturing has opened up possibilities for designers to explore alternative gear tooth profiles. This is particularly relevant in the realm of plastic gears, where optimized non-involute gears produced through 3D printing can address their primary drawbacks, such as surface durability and wear resistance. In this study, a comprehensive free-form optimization process was conducted to determine the optimal tooth profile that minimizes wear on 3D printed spur gears during operation. The tooth flank geometry was represented using a 4th order B-spline curve, and a genetic algorithm was employed to determine the optimum positions of the control points aiming to minimize wear depth across the tooth flanks. The spur gears were manufactured using Fused Deposition Modeling (FDM) with PLA material. The parameters of the additive manufacturing process were experimentally fine-tuned to achieve the best possible accuracy. To evaluate the performance of the optimized free-form gears, two case studies were implemented, demonstrating that the optimized gears achieved a remarkable reduction of average wear depth by more than 50% and a reduction of maximum wear depth by more than 69% compared to standard involute gears. To further validate the effectiveness of the optimization method, experiments were carried out using an FZG test rig. The profiles of the tooth flanks were measured on a Coordinate Measuring Machine (CMM) before and after the experiments to compare the wear depth against the standard involute gears. The results revealed a significant improvement in the wear resistance of the tooth flanks, with a reduction of wear depth of 44.1%.

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Section: Case Study #1mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Improving the wear resistance of 3D printed spur gears through a free-form tooth flank optimization process

Kalligeros,

Papalexis,

Georgiou

et al. 2023

MATEC Web Conf.

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“…Singh and Singh 33 discuss the effects of various techniques of tooth geometrical modifications to enhance the performance and durability of plastic gears. Failure behavior of polymer gear are also discussed in brief by Ghazali et al, 34 Jain et al, 35 and Kumar et al 36 Whereas the failure behavior of polymer gears under different loading conditions can be referred from the review work carried out by Singh and Singh. 37 As per the literature survey, the diversity of research work on polymer gears can be seen.…”

Section: Introductionmentioning

confidence: 99%

A review on materials and performance characteristics of polymer gears

Jain

Patil

2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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In this research work an extensive review on use of advance materials and performance of polymer gears. Further, literature on polymer gears has been divided into four divisions based on the type of gear material, performance characteristic, modifications, and manufacturing techniques. Materials like polyamide and acetal and their composites are focused due to their huge application quotient. Use of in total six grades that is, PA6, PA66, PA12, PA46, PA618, and PA645 as gear material have been identified. Use of glass and carbon fiber reinforcements in PA gears with varying percentage in a range of 20%–35% and 15%–30%, respectively have been observed. Failure and performance characteristics such as wear, thermal, fatigue, load, transmission, and operational have been illustrated and described in detail. Research studies to improve thermal performance of plastic gears by modifying gear tooth and its profile has also been discussed along with their effects. Application of advance manufacturing technique such as 3D printed additive manufacturing in producing plastic gears is also talked over in this article. This compiled review work aims to assist researchers in selection of plastic gear material and to explore various factors and parameters affecting the failure behavior and performance of plastic gears.

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“…As POM is one of a number of materials of interest in polymer gears, previous work has been summarised in recent literature reviews of the field e.g. [12][13][14]. More specific and pertinent previous studies include aspects such as gear meshing mechanisms [15][16][17], materials [18][19][20], and thermal analysis [21,22].…”

Section: Introductionmentioning

confidence: 99%

Wear Performance of Commercial Polyoxymethylene Copolymer and Homopolymer Injection Moulded Gears

Xu¹,

Gao²,

Vallé³

et al. 2021

Tribol. Ind.

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Polymer gears are an effective solution to lightweighting, which are highly demanded in the automotive industry. Acetal is one of the most widely used polymer gear materials. In this study, two commercial grades of acetal, homopolymer (POM-H) based and copolymer (POM-C) based, were injection moulded into gears with their wear performance compared. Noticeable differences were discovered in failure mechanism, and thermal and mechanical characteristics, which led to a difference in performance prediction. The service life of over two million cycles was expected under a torque up to 10 N m, with POM-H gears having 35% better service life than POM-C. The differences in the properties of POM-H and POM-C should be considered in future industrial applications such as the replacement for metal gears.

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A review on failure characteristics of polymeric gears

Cited by 11 publications

References 60 publications

Improving the wear resistance of 3D printed spur gears through a free-form tooth flank optimization process

Improving the wear resistance of 3D printed spur gears through a free-form tooth flank optimization process

A review on materials and performance characteristics of polymer gears

Wear Performance of Commercial Polyoxymethylene Copolymer and Homopolymer Injection Moulded Gears

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