Abstract
The performance of plastic gears in wide variety of power and motion transmission applications is rather limited due to weak mechanical properties and divergent mechanism of failures. A methodical simulation is carried out to analyze the gear performance with various gating system types, gate locations, and processing parameters via grey-based Taguchi optimization method. With the obtained optimum results in simulation stage, the flow patterns of polymer melt inside the mould during filling, packing, and cooling processes are studied and the plastic gear failures mechanism related to processing parameters are predicted. The output results in the future can be used as guidance in selecting the appropriate materials, improving part and mould design, and predicting the performance of the plastic gear before the real process of the part manufacturing takes place.
Highlights
Gears have been in use for more than three thousand years and commonly utilized in power and motion transmission under different loads and speeds
In order to find the optimum levels of melt temperature, mould temperature, packing pressure, packing time, injection time, and cooling time for the desired multiple quality characteristics of the PP moulded gear, the results in Table 4 are needed to be normalized as the range and unit in one data are different from the others
The analysis revealed that the melt temperature had the strongest correlation with the volumetric shrinkage and deflection in the moulded gear for the specific material selected
Summary
Gears have been in use for more than three thousand years and commonly utilized in power and motion transmission under different loads and speeds. Due to the fiscal and practical advantages, the demand of using plastics in gearing industry is significantly increased and indubitably continues in the future. Plastic gears can be produced by hobbing or shaping, likewise to metal gears or alternatively by injection moulding. Apart from that, the plastic gear tooth experiences complex stresses during service and can fail by divergent mechanism. Plastic base gears, in addition, are sensitive to temperature due to heat generation during service which resulted in surface fatigue and fatigue cracking at tooth root acceleration [8]. On the other report of Osman and Velex [9], plastic gears can fail due to contact fatigue or surface pitting as a result of dynamic tooth loads during the running operation
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