Abstract
In recent years, polymer gears have gradually become more widely employed in medium or heavy-duty conditions based on weight reduction in transmission systems because of low costs and low noise compared to metal gears. In the current industry, proposing a cost-effective approach to the manufacture of polymer gears is an important research issue. This paper investigates the wear performance of polymer gears fabricated with eight different kinds of materials using differential pressure vacuum casting and additive manufacturing techniques. It was found that both additive manufacturing and differential pressure vacuum casting seem to be an effective and cost-effective method for low-volume production of polymer gears for industrial applications. The gate number of one is the optimal design to manufacture a silicone rubber mold for differential pressure vacuum casting since the weld line of the polymer is only one. Polyurethane resin, 10 wt.% glass fiber-reinforced polylatic acid (PLA), or 10 wt.% carbon fiber-reinforced PLA are suggested for manufacturing gears for small quantity demand based on the deformation and abrasion weight percentage under process conditions of 3000 rpm for 120 min; epoxy resin is not suitable for making gears because part of the teeth will be broken during abrasion testing.
Highlights
The results clearly show that the gears fabricated by differential pressure vacuum casting (DPVC)
Polymer gears gears have have been been widely widely applied applied in systems due due to Polymer in transmission transmission systems to low low noise noise and low costs compared to metal gears
The main purpose of this study was to characterize and low costs compared to metal gears
Summary
Product developers need to overcome a tricky issue by making a small batch of prototypes for testing economy and feasibility. The polymer gear has some distinct advantages compared to the metal gear, including low weight, quietness of operation, and no need for external lubrication [1], and has been widely used in the automotive industry and consumer electronics. Additive manufacturing (AM) [2,3] has been defined as the process of building physical models by joining materials layer upon layer using computer numerical control data. The application of AM processes has increased in fabricating physical models across various industries because of its capability in manufacturing functional parts with complex geometries. The AM technology has been widely used to produce prototypes or physical models since it has the capacity to manufacture components with sophisticated geometric shapes
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