An Analysis of Polymer Gear Wear in a Spur Gear Train Made Using FDM and FFF Methods Based on Tooth Surface Topography Assessment

Pisula, J.; Budzik, Grzegorz; Turek, P.; Cieplak, Mariusz

doi:10.3390/polym13101649

Cited by 24 publications

(16 citation statements)

References 61 publications

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“…Polymer gears are used widely in many engineering applications, such as office appliances, mechatronic devices, household facilities, computer and laboratory equipment, medical instruments, etc. [ 1 , 2 , 3 , 4 ]. These polymer gears can be produced by classical cutting processes or, for large series production, by injection moulding [ 5 , 6 ].…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation of the Wear Behaviour of Coated Polymer Gears

et al. 2021

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A comprehensive experimental investigation of the wear behaviour of coated spur polymer gears made of POM is performed in this study. The three physical vapour deposition (PVD) coatings investigated were aluminium (Al), chromium (Cr), and chromium nitrite (CrN). Al was deposited in three process steps: By plasma activation, metallisation of Al by the magnetron sputtering process, and by plasma polymerisation. Cr deposition was performed in only one step, namely, the metallization of Cr by the magnetron sputtering process. The deposition of CrN was carried out in two steps: the first involved the metallization of Cr by the magnetron sputtering process while the second step, vapour deposition, involved the reactive metallisation of Cr with nitrogen, also by the magnetron sputtering process. The gears were tested on an in-house developed testing rig for different torques (16, 20, 24 and 30 Nm) and rotational speed of 1000 rpm. The duration of the experiments was set to 13 h, when the tooth thickness, and, consequently, the wear of the tooth flank was recorded. The experimental results showed that the influence of metallisation with aluminium, chromium, and chromium nitrite surface coatings on the wear behaviour of the analysed polymer gear is not significant. This is probably due to the fact that the analysed coatings were, in all cases, very thin (less than 500 nm), and therefore did not influence the wear resistance significantly. In that respect, an additional testing using thicker coatings should be applied in the further research work.

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Section: Introductionmentioning

confidence: 99%

Experimental Investigation of the Wear Behaviour of Coated Polymer Gears

et al. 2021

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“…The process and setup are more accurately described in [26]. The surface measurements enable assessment of the tooth geometry across the entire width of the toothed ring [35].…”

Section: Optical Measurementmentioning

confidence: 99%

Comprehensive Areal Geometric Quality Characterisation of Injection Moulded Thermoplastic Gears

et al. 2022

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Injection moulding is currently the most widely employed production method for polymer gears. Current standardised gear metrology methods, which are based on metal gear inspection procedures, do not provide the key information regarding the geometric stability of injection moulded gears and are insufficient for a thorough gear inspection. The study developed novel areal quality parameters, along with a so-called moulding runout quality parameter, with a focus on the injection moulding method. The developed parameters were validated on twenty-nine gear samples, produced in the same moulding tool using various processing parameters. The gears were measured using a high-precision structured-light 3D scanner. The influence of injection moulding process parameters on the introduced novel quality parameters was investigated. The developed moulding runout quality parameter proved to be effective in evaluating the shrinkage that can occur in the injection moulding process. The novel moulding runout parameter returned an average value of −21.8 μm in comparison to 29.4 μm exhibited by the standard parameter on all the gears, where the negative value points directly to mould shrinkages. The rate of cooling was determined to be the most influential factor for the shrinkage of the gear. The developed areal parameters demonstrated to be advantageous in characterising the deviations on the teeth more comprehensively.

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“…The mechanical properties were optimal for gears with a 2% weight proportion of nano clay. The durability of ABS, polyetheretherketone (PEEK) and polyetherimide (PEI) gears printed by the FFF process was evaluated by Pisula et al 19 The surface topography charts were analysed, and the highest wear resistance was observed in the PEEK gears. Karthik Pandian et al 20 studied the bending fatigue behaviour of SLS Nylon gears built-in 'flat' configuration, in which the direction of layer deposition was along the gear centre axis during the sintering process.…”

Section: Fatigue Performance Of Additively Manufactured Plastic Gearsmentioning

confidence: 99%

“…14,20 The evaluation of various aspects of SLS gears' performance has been limited, which warrants further assessments. • The fatigue performance of AM plastic gears has been commonly evaluated under dynamic conditions, [15][16][17][18][19] which encompasses contact fatigue as well as bending fatigue. However, investigations evaluating the individual effect of bending fatigue on the performance of AM plastic gears have been limited.…”

Section: Research Gaps and Objectivesmentioning

confidence: 99%

Effect of layer orientation on the single tooth bending fatigue strength of polymer gears manufactured by selective laser sintering

Pandian

Gautam

Selvaraj

2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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This study investigates the influence of tooth layer orientation on the bending fatigue behaviour of Nylon 12 spur gears manufactured by a selective laser sintering process in an ‘on-edge’ configuration. The test gears were submitted to single tooth bending fatigue tests, and the thermal response of gears was recorded using Infrared thermography. The surface morphology of failed teeth was examined using microscopy. The effect of tooth layer orientation on the fatigue strength of selective laser sintering gears was evaluated by testing each tooth configuration. The tooth configurations with the highest and lowest strength were 40° and 160°, respectively. The performance of selective laser sintering gears was compared with that of injection moulded Nylon 66 gears. The injection moulded, selective laser sintering 40°, and selective laser sintering 160° gear teeth were tested at multiple loads to investigate the high cycle fatigue and low cycle fatigue behaviour. The bending fatigue life was highest for the injection moulded gears in both low cycle fatigue and high cycle fatigue regimes. The surface temperature was higher in selective laser sintering gears, with 160° configuration exhibiting the highest temperature. The difference between the temperatures of selective laser sintering 40° configuration and injection moulded gear magnified as the applied load increased. Consequently, the strength of the selective laser sintering 40° configuration with respect to injection moulded gear deteriorated in the low cycle fatigue region. Fractography indicated that crack propagation in selective laser sintering 40° and selective laser sintering 160° configurations were cross-laminar and inter-laminar, respectively. In the cross-laminar mode of propagation, the crack propagation was impeded by the layer structure. However, the crack propagation was expedited in the inter-laminar mode, as the crack path was along the interlayer region, which presents a path of least resistance.

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An Analysis of Polymer Gear Wear in a Spur Gear Train Made Using FDM and FFF Methods Based on Tooth Surface Topography Assessment

Cited by 24 publications

References 61 publications

Experimental Investigation of the Wear Behaviour of Coated Polymer Gears

Experimental Investigation of the Wear Behaviour of Coated Polymer Gears

Comprehensive Areal Geometric Quality Characterisation of Injection Moulded Thermoplastic Gears

Effect of layer orientation on the single tooth bending fatigue strength of polymer gears manufactured by selective laser sintering

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