Abstract
This research work presents a modified mathematical method to estimate the specific wear rate of spur gears for specified service conditions by calculating the coordinates of the point on the involute of gear tooth profile. This work stands apart in a way that an entirely novel manufacturing process developed in-house is used to fabricate functionally graded materials (FGMs) based thermoplastic gears, which have never been explored before, and the specific wear rate of manufactured gears is estimated using the proposed method. FGM and homogeneous gears are manufactured by means of an especially designed mold and a punch. Polyamide 66 (PA66) filled with 15 wt. % and 30 wt. % glass fibers is used to fabricate FGM and homogeneous gears. Neat PA66 gear is also fabricated for comparative study. Gradation in FGM gears is verified by scanning electron microscope (SEM) analysis and hardness measurements. Thermal and wear tests of the gears are conducted over a range of rotational speed (500–1700 rpm) and torque (0.8–3.2 N·m). Thermal and wear behavior of developed gears is successfully analyzed using Taguchi methodology and analysis of variance (ANOVA). The service life of FGM gears is found to be superior as compared to unfilled and homogeneous gear. FGM gear filled with 30 wt. % glass fiber exhibited minimum gear tooth surface temperature and specific wear rate among all the fabricated gears.
Issue Section:
Friction and Wear
References
1.
Mao
,
K.
,
Li
,
W.
,
Hooks
, C.
J.
, and Walton
,
D.
, 2010
,
“Polymer Gear Surface Thermal Wear and Its Performance
Prediction
,” Tribol. Int.
,
43
(1–2
), pp.
433
–439
.2.
Imrek
,
H.
, 2009
,
“Performance Improvement Method for Nylon 6 Spur
Gears
,” Tribol. Int.
,
42
(3
), pp.
503
–510
.3.
Breeds
,
A. R.
,
Kukureka
, S.
N.
, Mao
,
K.
,
Walton
,
D.
, and
Hooke
, C.
J.
, 1993
, “Wear
Behavior of Acetal Gear Pairs
,” Wear
,
166
(1
), pp.
85
–91
.4.
Imrek
,
H.
, 2009
,
“Width Modification for Gears With Low Contact
Ratio
,” Meccanica
,
44
(5
), pp.
613
–621
.5.
Mao
,
K.
,
Hooke
, C.
J.
, and Walton
,
D.
, 2006
,
“Acetal Gear Wear and Performance Prediction Under
Unlubricated Running Condition
,” Lubr.
Sci.
, 23
(3
), pp.
137
–152
.6.
Wu
,
S.
, and
Cheng
, H.
S.
, 1993
, “Sliding
Wear Calculation in Spur Gears
,” ASME J.
Tribol.
, 115
(3
), pp.
493
–500
.7.
Kim
,
C. H.
, 2006
,
“Durability Improvement Method for Plastic Spur
Gears
,” Tribol. Int.
,
39
(11
), pp.
1454
–1461
.8.
Senthilvelan
,
S.
, and
Gnanamoorthy
,
R.
, 2006
,
“Effect of Gear Tooth Fillet Radius on the Performance of
Injection Molded Nylon 6/6 Gears
,” Mater.
Des.
27
(8
), pp.
632
–639
.9.
Duzcukoglu
,
H.
, 2009
,
“Study on Development of Polyamide Gears for Improvement of
Load-Carrying Capacity
,” Tribol. Int.
,
42
(8
), pp.
1146
–1153
.10.
Duzcukoglu
,
H.
,
Yakut
,
R.
, and
Uysal
,
E.
, 2010
,
“The Use of Cooling Holes to Decrease the Amount of Thermal
Damage on a Plastic Gear Tooth
,” J. Fail. Anal.
Prev.
, 10
(6
), pp.
545
–555
.11.
Duzcukoglu
,
H.
, 2009
,
“PA 66 Spur Gear Durability Improvement With Tooth Width
Modification
,” Mater. Des.
,
30
(4
), pp.
1060
–1067
.12.
Senthilvelan
,
S.
, and
Gnanamoorthy
,
R.
, 2004
,
“Wear Characteristics of Injection-Molded Unfilled and
Glass-Filled Nylon 6 Spur Gears
,” Proc. Inst. Mech.
Eng. Part J
, 218
(6
), pp.
495
–502
.13.
Senthilvelan
,
S.
, and
Gnanamoorthy
,
R.
, 2008
,
“Influence of Reinforcement on Composite Gear
Metrology
,” Mech. Mach. Theory
,
43
(9
), pp.
1198
–1209
.14.
Dighe
,
A. D.
,
Mishra
, A.
K.
, and
Wakchaure
, V.
D.
, 2014
,
“Investigation of Wear Resistance and Torque Transmission
Capacity of Glass Filled Polyamide and PEEK Composite Spur
Gears
,” Int. J. Eng. Adv. Technol.
,
3
(3
), pp.
299
–303
.http://citeweb.info/2014042748815.
Yakut
,
R.
,
Duzcukoglu
,
H.
, and
Demirci
, M.
T.
, 2009
, “The
Load Capacity of PC/ABS Spur Gears and Investigation of Gear
Damage
,” Arch. Maters. Sci. Eng.
,
40
(1
), pp.
41
–46
.http://yadda.icm.edu.pl/yadda/element/bwmeta1.element.baztech-article-BSL7-0038-002016.
Tsukamoto
,
N.
,
Maruyama
,
H.
, and
Mimura
,
H.
, 1992
,
“Effect of Reducing Friction of Polyacetal in
Gears
,” Trans. JSME Ser. C
,
58
(545
), pp.
231
–237
.17.
Gurunathan
,
C.
,
Kirupasankar
,
S.
, and
Gnanamoorthy
,
R.
, 2011
,
“Wear Characteristics of Polyamide Nanocomposite Spur
Gears
,” Proc. Inst. Mech. Eng. Part J
,
225
(5
), pp.
299
–306
.18.
Mao
,
K.
, 2007
,
“A New Approach for Polymer Composite Gear
Design
,” Wear
,
262
(3–4
), pp.
432
–441
.19.
Li
,
W.
,
Wood
,
A.
,
Weidig
,
R.
, and
Mao
,
K.
, 2011
,
“An Investigation on the Wear Behaviour of Dissimilar Polymer
Gear Engagements
,” Wear
,
271
(9–10
), pp.
2176
–2183
.20.
Kieback
,
B.
,
Neubrand
,
A.
, and
Riedel
,
H.
, 2003
,
“Processing Techniques for Functionally Graded
Materials
,” Mater. Sci. Eng. A
,
362
(1–2
), pp.
81
–105
.21.
Al-Qrimli
, H.
F.
, Oshkour
,
A. A.
, and
Ismail
, F.
B.
, 2015
, “Material
Design Consideration for Gear Component Using Functional Graded
Materials
,” Int. J. Mater. Eng. Innovation
,
6
(4
), pp.
243
–256
.22.
Siddhartha
, and
Singh
, A.
K.
, 2015
,
“Mechanical and Dry Sliding Wear Characterization of Short
Glass Fiber Reinforced Polyester-Based Homogeneous and Their Functionally
Graded Composite Materials
,” Proc. Inst. Mech. Eng.,
Part L.
, 229
(4
), pp.
274
–298
.23.
Singh
,
A. K.
,
Siddhartha
,
Yadav
,
S.
, and
Singh
, P.
K.
, 2016
,
“Repercussion of Manufacturing Techniques on Mechanical and
Wear Peculiarity of ZnO Particulate-Filled Polyester
Composites
,” Polym. Compos.
, epub.24.
Singh
,
A. K.
, and
Siddhartha
,
2015
, “Mechanical and Tribological Peculiarity
of Nano-TiO2-Augmented, Polyester-Based Homogeneous Nanocomposites and Their
Functionally Graded Materials
,” Adv. Polym.
Technol.
, epub. 25.
Siddhartha
,
Singh
, A.
K.
, and Yadav
,
S.
, 2015
,
“Exploring the Possibility of Utilization of Red Mud Epoxy
Based Functionally Graded Materials as Wear-Resistant Materials Using
Taguchi Design of Experiment
,” Adv. Polym.
Technol.
, 36
(1
), pp.
5
–22
.26.
Siddhartha
,
Patnaik
,
A.
,
Satapathy
,
A.
, and
Bhatt
, A.
D.
, 2011
, “A Study
on Modified Mechanical and Wear Characteristics of Epoxy-Particulate Filled
Homogenous Composites and Their Functionally Graded
Materials
,” ASME J. Tribol.
,
133
(1
), p. 011601
.27.
Mao
,
K.
,
Li
,
W.
,
Hooke
, C.
J.
, and Walton
,
D.
, 2009
,
“Friction and Wear Behavior of Acetal and Nylon
Gears
,” Wear
,
267
(1–4
), pp.
639
–645
.28.
Lancaster
, J.
K.
, 1968
,
“Relationships Between the Wear of Polymers and Their
Mechanical Properties
,” Proc. Inst. Mech.
Eng.
, 183
(16
), pp.
98
–106
.https://doi.org/10.1243/PIME_CONF_1968_183_283_0229.
Hutchings
,
I. M.
, 1992
,
Tribology: Friction and Wear of Engineering Materials
,
Edward Arnold
,
London
.30.
Buckingham
,
E.
, 1963
,
Analytical Mechanics of Gears
, Dover
Publications
, Mineola,
NY
.31.
Agarwal
,
B. D.
,
Broutman
, L.
J.
, and
Chandrashekhara
,
K.
, 2006
,
Analysis and Performance of Fibre Composites
, 3rd
ed., Wiley
, New
York
.32.
Glen
,
S. P.
, 1993
,
Taguchi Methods: A Hand on Approach
,
Addison-Wesley
, New
York
.33.
Koffi
,
D.
,
Gauvin
,
R.
, and
Yelle
,
H.
, 1985
,
“Heat Generation in Thermoplastic Spur
Gears
,” ASME J. Mech. Transm. Autom. Des.
,
107
(1
), pp.
31
–36
.34.
Gauvin
,
R.
,
Girard
,
P.
, and
Yelle
,
H.
, 1983
,
“An Improved Method to Establish the Heat Transfer
Coefficient on Gear Tooth Surface
,” Sixth World
Congress Theory Machines and Mechanisms
, New Delhi, India, Dec.
15–20, Vol. 2
, pp.
864
–867
.35.
Liu
,
R.
,
Burns
, D.
J.
, and Yelle
,
H.
, 1987
,
“Flank Temperature Profile for Thermoplastic Spur
Gear
,” Seventh World Congress Theory Machines and
Mechanisms
, Seville, Spain, Sept. 17–22, Vol.
2
, pp.
1285
–1288
.36.
Dominik
,
V. R.
,
Donald
, V.
R.
, and Marlene
,
G. R.
, 2000
,
Plastics Design Handbook
, Kluwer Academic
Publications
, Boston,
MA
.37.
Senthilvelan
,
S.
, and
Gnanamoorthy
,
R.
, 2007
,
“Effect of Rotational Speed on the Performance of
Unreinforced and Glass Fiber Reinforced Nylon 6 Spur Gears
,”
Mater. Des.
, 28
(3
), pp.
765
–772
.38.
Senthilvelan
,
S.
, and
Gnanamoorthy
,
R.
, 2004
,
“Damage Mechanisms in Injection Molded Unreinforced, Glass
and Carbon Reinforced Nylon 66 Spur Gears
,” Appl.
Compos. Mater.
, 11
(6
), pp.
377
–397
.39.
Ochola
,
R. O.
,
Marcus
,
K.
,
Nurick
, G.
N.
, and Franz
,
T.
, 2004
,
“Mechanical Behaviour of Glass and Carbon Fiber Reinforced
Composites at Varying Strain Rates
,” Compos.
Struct.
, 63
(3–4
), pp.
455
–467
.40.
Goldberg
,
R. K.
,
Roberts
, G.
D.
, and
Gilat
,
A.
, 2003
,
“Incorporation of Mean Stress Effects Into the Micro
Mechanical Analysis of the High Strain Rate Response of Polymer Matrix
Composites
,” Composites Part B
,
34
(2
), pp.
151
–165
.41.
Tsukamoto
,
N.
,
Yano
,
T.
, and
Sakai
,
H.
, 1982
,
“Noise and Transmission Efficiency Under Deformation of Tooth
Form of Nylon Gear
,” Bull. JSME
,
25
(207
), pp.
1465
–1473
.42.
Tsukamoto
,
N.
, 1981
,
“Investigation About the Strength of Plastic Gears (3rd
Report; Strength of the Nylon Gear Meshing With the Steel Gear Which Was Cut
by Semi Topping Hob)
,” Bull. JSME
,
24
(198
), pp.
2184
–2193
.43.
Mertens
,
A. J.
, and
Senthilvelan
,
S.
, 2015
,
“Effect of Mating Metal Gear Surface Texture on the Polymer
Gear Surface Temperature
,” Mater. Today:
Proc.
, 2
(4–5
), pp.
1763
–1769
.44.
Wang
,
Q.
,
Zhang
,
X.
, and
Pei
,
X.
, 2010
,
“Study on the Synergistic Effect of Carbon Fiber and Graphite
and Nanoparticle on the Friction and Wear Behavior of Polyimide
Composites
,” Mater. Des.
,
31
(8
), pp.
3761
–3768
.Copyright © 2018 by ASME
You do not currently have access to this content.
