Composite Gear Research Articles

High cycle fatigue behaviour of autoclave-cured woven carbon fibre-reinforced polymer composite gears

The high cycle fatigue behaviour of autoclave-cured carbon fibre-reinforced polymer (CFRP) composite gears is investigated. The CFRP gears were milled from a composite plate and tested in mesh with a steel drive gear under five torque loads ranging between 0.4 and 0.8 Nm in unlubricated conditions. A detailed gear damage analysis is conducted by employing scanning electron microscopy and high-resolution optical microscopy. Epoxy matrix microcracking is found to be the damage mechanism that leads to the final delamination failure. CFRP gears exhibited a significantly improved performance and a longer fatigue lifespan in comparison with the polymer and polymer composite gears.

Design and Analysis of Spur Gear Using Composite Material

Spur gears are the simplest and widely used in power transmission. In recent years it is required to operate machines at varying load and speed. Gear teeth normally fail when load is increased above certain limit. Therefore, it is required to explore alternate materials for gear manufacturing. Composite materials provide adequate strength with weight reduction and they have emerged as a better alternative for replacing metallic gears. Composites provide much improved mechanical properties such as better strength to weight ratio, more hardness, and hence less chances of failure. So, this work is concerned with replacing metallic gear with composite material to improve performance of machine and to have longer working life. Efforts have also been carried out for modeling using 3D modelling software called SOLIDWORKS and finite element analysis of gears using ANSYS. Composite gears have been manufactured by stir casting, which is economical method. Composite gears offer improved properties over steel alloys and these can be used as better alternative for replacing metallic gears.

Design and Analysis of Composite Spur Gear

Construction of the gear system to research the reduced weight and stress distribution of casting metal and carbon fibre. In a hydraulic power transfer device in industrial spinning machines, gearing is one of the most important elements. Given their high level of certainty and controllability, in future devices, gears might dominate as perhaps the most powerful ways of sending electricity. Furthermore, the growing change in the sector to companies like car manufacturing and office automation devices from key sectors like naval boats would entail the refined use of equipment technologies. Model the spur gear model using modelling techniques. To examine the effects study on casting iron and infrastructure projects. For casting structural steel items, displacement charging should really be examined. It is important to compare and evaluate the composite gear with the current cast steel gear.

Investigation of the durability and performance of autoclave-cured, woven carbon fiber-reinforced polymer composite gears in mesh with a steel pinion

Wear mechanisms and failure modes were investigated for autoclave-cured, woven carbon fiber-reinforced polymer (CFRP) composite gears in a mesh with a surface-hardened, 42CrMo4 steel pinion. The reference gears (m = 1 mm, b = 2 mm, z = 20) were tested at torque levels ranging from 0.4 Nm to 0.8 Nm. The temperature was monitored with a thermographic camera, while the gear damage and wear volume were analyzed and measured every 2 million cycles. The relationship between wear volume against the number of cycles was obtained. Scanning electron microscopy revealed two- and three-body abrasive, oxidative, and fatigue wear, and progressive de-laminations during the sliding and rolling of the gears. The CFRP composite gears exhibited higher wear resistance than the polymer ones.

Cad for Gears Part 1 Helical and Double Helical Gears.(Dept.M)

The aim of this paper is to construct a software containing a complete design procedure and detailed drawing for spur, helical and double helical gears. This software can be executed on all the IBM personal computers XT/AT or compatibles. The main elements of the design In this program are : input data, type end shape of gear tooth system (IS. US, BS and DIN), module, minimum number of teeth to avoid interference, tooth profile modification, centre distance, contact ratio, face width, helix angle, material, equations for bending strength (Lewis, modified Lewis and Buckingham) and surface durability, and load carrying capacity for bending strength and surface durability using ISO, AGMA and BS equations with constant or variable tooth load. Many equations and practical formulae are selected for making the gear construction integer gear, solid gear, gear with web, gear with web and holes, gear with arms, gear with Two walls and composite gear). With running the software. full specifications, geometry, kinematics, loads, stresses and detailed drawing of the gears are obtained according to the input data. Different examples are selected to show the variety of the Output data and the strength of the software. Also these runs show the sava in time and accuracy of the results.

Cad for Gears Part 2 Bevel Gears.(Dept.M)

The aim of this paper is to construct a software containing a complete design procedure and detailed drawing for bevel gears (straight, skew, zerol and spiral). This software can be executed on all the IBM personal computers XT/AT or compatibles. The main elements of the design in this program are: input data, type of bevel gear, type and shape of gear tooth system (ISO, US, BS, DIN and Gleason), module, virtual number of teeth, minimum number of teeth to avoid Interference, tooth profile modification, shaft angle, contact ratio, face width, spiral angle, force analysis, sliding velocity and efficiency, material, equations for bending strength (Modified Lewis, Buckingham, AGMA and Gleason) and surface durability, also load carrying capacity for bending strength and surface durability using ISO, AGMA, Gleason and 8S equations with constant or variable tooth load. Many equations and practical formulae are selected for making the gear construction (integar gear, solid gear, gear with web, gear with web and holes, gear with arms and composite gear). With running the software, full specifications, geometry, kinematics. loads, stresses and detailed drawing of the gears are obtained according to the input data. Different examples are selected 10 show the variety of the output data and the strength of the software. Also these runs show the save in time and accuracy of the results.

The Prediction of Stress and Strain Behaviors in Composite Gears using FEM

Metal matrix composite (MMC) gears are used as a major component in the industry and are responsible for providing high-quality power transfer at high speeds. High quality, including high strength and impact-resistance, low brittleness, and long lifetime, is very important and needed in the industry. Gears are made of different materials, and, nowadays, researchers and industrialists have turned to designing, manufacturing, and using composite gears more than other gears due to their low weight, high hardness and strength, and better mechanical properties. In this research, the stress and strain behaviors are predicted in the composite gears made of aluminum silicon carbide with 3 different SIC volume fractions, namely 55 vol.%, 40 vol.%, and 30 vol.%, and with specifications of (Al45/SIC55, Al60/SIC40, and Al70/SIC30) and gears made of aluminum oxide with 3 different alumina weight fractions, namely 94 wt.%, 96 wt.%, and 99.5 wt.% to evaluate and compare the stress behavior due to different forces exerted on a single gear tooth in MMC gears. The Al45/SIC55 composite experienced the largest stress compared to other composites such as Al60/SIC40 and Al70/SIC30. The strain values (unlike the stress values) reduced with increasing in the volume fraction of the SIC reinforcement. Moreover, 94% aluminum oxide composite showed larger stress compared to 96% aluminum oxide and 99.5% aluminum oxide. The spur gear is designed and analyzed using SOLID WORKS and ANSYS Workbench softwares.

Robust control design for a planar humanoid robot arm with high strength composite gear and experimental validation

Aiming at uncertainties and variable loads of the robot arm, a nonlinear control algorithm is proposed. The design of the proposed control is based on the engineering practice of the planar humanoid robot arm with high strength composite gear. The proposed control, consisting of a PD control portion and a robust control portion, retains the dynamic characteristics of the system and realizes based on error. Theoretical analysis shows that the proposed control can guarantee the uniform boundedness and uniform ultimate boundedness. Based on the humanoid robot arm, the experimental validation with the proposed control is carried out and compared with the PID control. Numerical simulations and experimental results show that the proposed control can effectively deal with load changes and parameter uncertainties, and the trajectory tracking accuracy of the robot is improved significantly with the proposed control.

Analitička procena uticaja koeficijenta kliznog trenja na kontaktni pritisak, trajnost i habanje cilindričnih zupčanika

The research of influence of sliding friction coefficient on durability is carried out for gear train containing steel wheels and metal-polymer gear trains containing polyamide gears reinforced with carbon and glass dispersion fibers. The teeth engagement conditions (two teeth pairs - single tooth pair - two teeth pairs) and the change of teeth tribocontact interaction conditions due to wear are also taken into account. The gear train containing the carbon-filled composite gear has the highest durability in comparison with other types in all ranges of change of sliding friction coefficient. The highest maximum contact pressures will be at the point of entry into the one-pair engagement. The change of initial maximum contact pressures in gear train due to tooth wear was also investigated and its regularities were established. The kinetics of the tooth profile wear was studied. It is established that the maximum wear will be at the point of entry into the one-pair engagement. Close to it will be the wear at the entrance into the two-pair engagement. The course of wear at different points of engagement for the studied gear trains containing steel toothed wheels and gear trains containing steel and composite gears is almost the same except for the point of the teeth exit from the engagement.

Design and Selection of Material for Plastic Gears

The use of plastic and polymer composite gears is increasing because of their low cost, lightweight and quiet operation compared to metal gears. Plastic gears find application in printers, cameras, timers, counters, etc. Four different combinations of materials for pinion and gear were selected in the present work, and a comparative study was done to investigate mechanical and thermal properties analytically. Analytical results were validated using SOLIDWORKS and ANSYS. Design 1 and Design 2 were found out to be preferable designs. Maximum principal and maximum shear stress generated were minimum for Design 1 (pinion of Polycarbonate and gear of Acetal copolymer). Simultaneously, the deformation and temperature rise were minimum for Design 2 (pinion of Nylon 66 and gear of Acetal copolymer).

A numerical simulation of the influence of torque on the performance of composite gears

The object of this study is the analysis of stresses and deformations using a numerical simulation of the influence of the torque transmitted by the actions of a pinion and a wheel made with a new HDPE40 composite material.The methodology of the gears meshing is presented along with the applied forces that induce the stresses and deformations. The influence of the geometrical characteristics of the teeth and the impact of operating conditions on the distribution of the stresses and deformations are studied. The changes in the gears performance as a function of wear was investigated. The studies showed that as the torque increases, the contact and bending stresses at the root increase and when the wear increases the bending stress at the root increases but the contact stress does not follow a definite law.

Design of helical gear with carbon reinforced EN36 steel for two stage constant mesh gearbox weight reduction

Engineering design is an iterative process that requires to be dealt with all feasible design solutions in order to arrive at a desired objective. Gear drives are considered as the critical components in a mechanical power transmission system. It is possible that gears will predominate as the most effective means of transmitting power in future machines due to their high degree of reliability and compactness. With the advancing technology in recent years, the machines are demanding varying speed and load. Over the years, research has been done predominantly on gears to minimize or to reduce the failures and for optimal design. The main aim of this work is to design and analyse the hybrid composite gears for two stage constant mesh helical gearbox and to compare the stress and deformation results with and without the inclusion of Carbon Fibre Reinforced (CFR) material. The objective of this research work is to reduce weight and rotational inertia of the entire assembly by using Hybrid Helical Gears. Carbon Fibre Standard UT Prepreg was selected for this study because of its high strength to weight ratio. By comparing the weights of EN36 Steel Gear and Hybrid Gear, a 25.3% reduction in weight was observed. This research work illuminates the replacement of EN36 alloy steel gear in terms of stresses and deformation with an added advantage of reduced weight and rotational inertia of the helical gear by using EN36/Carbon Fibre Composite material while considering the safety of the component in the application of two-stage constant mesh gearbox.

Design and optimization of nylon 66 reinforced composite gears using genetic algorithm

Lightweight and medium strength gears are very important in robotics and toys industries. In this paper, a short fiber reinforced thermoplastic materials are implemented to design the spur gears. Four types of materials with different compositions and main element is nylon 66 is considered in this present work. Initially, a robotic gear model is optimized using genetic algorithm by considering deformation and bending stress as constrains. These data are used to prepare the 3D model in CATIA software. Further analysis was planned in simulation tool called ABAQUS. Static structural, frequency and critical load analysis is performed using this software. The study on how dynamic loads on shaft are affected when the gear assembly rotates is done in this work. The results are compared to define the optimum and best suitable material for lightweight gears.

Performance evaluation of composite gears composed of POM, CNTs, and PTFE

AbstractThe main focus of this work is to enhance the load bearing capacity and life of the polyoxymethylene (POM) gears. For this purpose, composites with varying weight fractions of silane treated carbon nanotubes (CNTs), lubricating additive polytetrafluoroethylene (PTFE) and synergistic combination of both CNTs and PTFE were fabricated by melt compounding using twin screw extruder followed by injection molding. Tensile properties and wear behavior of the developed composites are evaluated. Further, test spur gears were fabricated with the developed composites and their performance is evaluated using power absorption type gear test rig at different torques and rotational speeds. Composite gears with 1 wt% silanized CNTs and composite gears with 10 wt% PTFE and 1 wt% silanized CNTs exhibited better performance at all the applied toques and rotational speeds.

Gear-Shift Device for Crane Gearboxes

A gear-shift device based on rollers is proposed for a gearbox with composite gears and built-in clutches. For the sake of speed, the drive is an electric step motor with a combination of a screw pair and a wedge mechanism at the shaft. That increases the controllability of the clutch.

Gear shifting in gearboxes of crane mechanisms

A device for gear shifting in a gearbox with composite gears with integrated couplings in which rolling bodies are used is proposed. For device performance, the drive is carried out from a stepper motor with a combination of a screw pair and a wedge mechanism on its shaft, which increases the control effect on the coupling. Keywords gearbox, variable gear ratio, gear wheel, coupling, stepper motor, screw pair, wedge mechanism. remizovich_uv@sibadi.org

Investigation of GFRP Gear Accuracy and Surface Roughness Using Taguchi and Grey Relational Analysis

Glass fiber reinforced polymer (GFRP) composite gear is used in a number of applications where fine motion transmission and silent rotation is required. In order to increase its usage there is a need to increase the quality of gear. Shrinkage problem is associated with injection molded gear. In present case blank is prepared by injection molding and teeth are cut on gear shaper by which metrology can be controlled by optimizing the machining parameters. An analysis of variance was applied on 27 experiments to validate the process and found out that rotary feed is at rank 1 which is 0.15[Formula: see text]mm/stroke, cutting fluid ratio is at rank 2 which is 12%, cutting speed is at rank 3 which is 240 stroke/min, fluid flow rate is at rank 4 which is 30 ml/min. By using these parameters optimum performance obtained is 0.213[Formula: see text]mm root diameter deviation (RD), 0.165[Formula: see text]mm tooth thickness variation (TT) and 1[Formula: see text][Formula: see text]m roughness average (Ra) with grey relational grade of 0.8318. The optimum response provided the best value of RD, TT and Ra for the range included in experimental results which is 0.138 to 0.416[Formula: see text]mm, 0.012 to 0.187[Formula: see text]mm and 1.2 to 2.43[Formula: see text][Formula: see text]m respectively. Surface roughness improvement in this work is 49.8% higher as compared to result available in literature.

Design and development of epoxy hybrid composite gears for low-powered application

ABSTRACT Gears are known to be useful in rotating motion transfer or power transmission from small product to larger, used everywhere. It was initially metallic foundation but now the polymeric material gear of a day is quite useful for purposes of small power transmission. High-strength polymer currently synthesises therefore very accurately in applications, so plastic gears replace metal gears particularly in low-powered applications. The replacement of metal gears by plastic gears continues in automobiles appliances and machinery due to its low noise, low wear, self-lubrication, economically, low weight, simple design and manufacturing merits. This paper deals with the effectiveness of using hybrid epoxy composites while designing spur gears. The epoxy’s ability to absorb water is much less than nylon. Here hybrid composites are created by mixing different SiO2 weight percentage and two layers of glass fibre simultaneously.

Friction Welding of Cast Iron and Phosphor Bronze

There is sometimes a need to fabricate machine parts that have the best properties of multiple materials while being economical at the same time. A prime example of such a scenario is with gears. Gears made out of cast iron are a poor choice because cast iron has poor impact resistance and is vulnerable to corrosion. The addition of phosphor bronze as an annulus to the cast iron hub in a composite gear provides the gear with those valuable resistances along with a superior intermeshing with mated gears. However, joining dissimilar materials such as cast iron to phosphor bronze is challenging when conventional welding techniques are employed. To overcome it, applying friction welding to join cast iron to phosphor bronze is focused in this thesis. The obtained results are analyzed and optimized for this particular combination of materials to facilitate their use in gears. The results show that there is an increased accumulation of graphite at the weld joints between cast iron and phosphor bronze for trials at higher (rotational) welding speeds, which leads to less favorable mechanical properties. At lower welding speeds, sound joints with acceptable mechanical and metallurgical properties were obtained.

Influence of Metal Foam Properties on Performance of Polymer Composite Spur Gear

The present study aims at developing light weight polymer composite spur gear and improving the performance. Various types of reinforcements and fillers have been used in the polymer gears in order to enhance the performance. There is some evidence in the literature that the metal foamsexhibit significant mechanical properties. The idea here is to use metal foam as a reinforcement material in polymer spur gear and to investigate the performance. The main objective of the present study is to investigate the influence of metal foam properties on the performance of polymer composite spur gear. Two part epoxy adhesive was used to fabricate spur gears. Two different metal foamslike aluminium and nickel with different porosity levels were used in order to have different properties of foams. The epoxy adhesive mixture was cast on the metal foam sheet, and gears were cut by abrasive water jet cutting process after curing of adhesive. The reinforced and unreinforced polymer gears were tested by an indigenously developed gear test rig with standard gear made of mild steel. The testing was carried out at different torque levels and at a constant speed, and the number of cycles was monitored. In the results, the metal foam reinforced gears show better performance than unreinforced polymer gear. In the case of polymer composite gear, nickel foam which has larger tensile strength, flexural strength and smaller porosity level shows better performance comparatively.It is concluded that choosing metal foam with better strength and smaller porosity help us improve the performance of the polymer composite gears.