Prediction of the Service Life of Metal-Polymer Gears Made of Glass and Carbon Fibre-Reinforced Polyamide, Considering the Impact of Height Correction

Abstract

Calculation methods for predicting the service life of metal-polymer gears with height correction are proposed. Two methods for gear service life estimation are presented: a simplified method that assumes constant tooth interaction conditions and an improved method that takes into account wear-induced changes in tooth interaction conditions. Spur cylindrical gears with a steel gear and a pinion made of polyamide composite reinforced with carbon and glass fibres are studied. The effect of height correction on the service life of the gears is examined, considering the type of tooth engagement. It is established that with the improved method the service life of the gear is by up to 1.3 times longer than that calculated by the simplified method at optimal height correction coefficients. Optimal service life of the gear is achieved when the correction coefficients are x 1 = -x 2 = 0.1. The effect of the coefficient of friction on gear service life is investigated. It is found that the service life of the gear with a carbon fibre-reinforced pinion is by 8.1...9.3 times longer than that of the gear with a glass fibre-reinforced pinion.

Modelling of contact and tribotechnical parameters of metal–polymer gears taking into account wear and correction of teeth

“…According to Chernets, 19 Chernets and Kornienko 20 Chernets et al, 21 Chernets et al, 22 and Chernets and Chernets 23 the teeth linear wear h ′ kj of the MP gears (Figure 1) at selected points j of their contact during one interaction is determined by the formula: where j = 1, 2, 3, …, s , t = 2 b j / v 0 , v 0 = ω 1 r 1 sinα, τ S = 0.5 R m for polymer composites, and τ S = 0.35 R m for steel.…”

“…Two methods were used to calculate the service life of gears: 20–25 simplified – Under constant conditions of teeth tribocontact interaction in the engagement when p j max = const , h ′ kj = const and the total teeth wear h max = n k h ′ kj ; improved (cumulative – accumulative) – Under variable conditions of teeth tribocontact interaction in the engagement, that is, at p jh max = var and h ′ kjn = var after each revolution (discrete interaction) or after a certain number of revolutions (block interaction). According to the simplified method, 22,23 the minimum durability t min before achieving the acceptable wear h k* at a certain point of contact is calculated as follows: When applying the improved method with variable conditions of tribocontact interaction, the procedure for calculating the durability is more complicated. 22,23 Wear of the teeth causes an increase in the initial radii of profile curvature, which leads to a decrease in the maximum contact pressures p j max and increases the width of the contact area 2 b j .…”

“…In Chernets et al, 18 Chernets, 19 and Chernets and Kornienko, 20 the author's modified method of calculation of MP gears load carrying capacity, wear and durability is given. The developed technique is based on the principles of known computational method for gears with metal-toothed wheels.…”

“…This paper uses the computational method developed by the authors 19,20 by mathematically modeling a comprehensive assessment of tribotechnical (minimum gears durability, linear teeth wear) and contact parameters (maximum contact pressures and their transformation during composite pinion teeth wear) in MP gears. The modeled gears are MP spur gears with a pinion made of polyamide PA6 filled with dispersed glass or carbon fibers, respectively, as used by Shil’ko and Starzhinskii.…”

A novel prediction approach of polymer gear contact fatigue based on a WGAN‐XGBoost model

“…For instances, Mao et al 8 proposed an approach for acetal gear transition torque prediction, which was based on the link between polymer gear wear rate and its surface temperature. Myron et al 18 proposed calculation methods for predicting the service life of metal‐polymer gears with height correction, and they found that with the improved method, the service life of the gear was by up to 1.3 times longer. However, with the emergence and development of artificial intelligence technology, the life prediction accuracy of the traditional method is too low, which can no longer meet the anti‐fatigue design of the new generation of polymer gears.…”