Engineers and designers can’t view plastic material gears as just metallic gears cast in thermoplastic. They need to pay attention to special issues and factors unique to plastic material gears. In fact, plastic gear style requires focus on details which have no effect on metallic gears, such as heat build-up from hysteresis.

The essential difference in design philosophy between metal and plastic gears is that metal gear design is founded on the strength of an individual tooth, while plastic-gear design recognizes load sharing between teeth. In other words, plastic teeth deflect more under load and spread the load over more teeth. In most applications, load-sharing increases the load-bearing capability of plastic material gears. And, consequently, the allowable stress for a specified number-of-cycles-to-failure boosts as tooth size deceased to a pitch around 48. Little increase is seen above a 48 pitch due to size effects and various other issues.

In general, the following step-by-step procedure will create a good thermoplastic gear:

Determine the application’s boundary conditions, such as temp, load, velocity, space, and environment.
Examine the short-term material properties to determine if the initial performance levels are adequate for the application.
Review the plastic’s long-term house retention in the specified environment to determine whether the performance amounts will be maintained for the life span of the part.
Calculate the stress amounts caused by the various loads and speeds using the physical house data.
Evaluate the Rotary Vane Vacuum Pumps calculated values with allowable strain amounts, then redesign if had a need to provide an sufficient safety factor.
Plastic material gears fail for most of the same reasons metal types do, including wear, scoring, plastic flow, pitting, fracture, and fatigue. The cause of these failures is also essentially the same.

One’s teeth of a loaded rotating gear are at the mercy of stresses at the main of the tooth and at the contact surface area. If the gear is lubricated, the bending stress is the most important parameter. Non-lubricated gears, however, may degrade before a tooth fails. Therefore, contact stress may be the prime factor in the design of the gears. Plastic gears will often have a complete fillet radius at the tooth root. Thus, they aren’t as susceptible to stress concentrations as metallic gears.

Bending-stress data for engineering thermoplastics is founded on fatigue tests run at specific pitch-line velocities. As a result, a velocity factor should be found in the pitch collection when velocity exceeds the check speed. Continuous lubrication can boost the allowable tension by one factor of at least 1.5. As with bending tension the calculation of surface contact stress takes a number of correction factors.

For example, a velocity factor is used when the pitch-range velocity exceeds the check velocity. In addition, a factor is used to account for changes in operating temperatures, gear components, and pressure angle. Stall torque is usually another factor in the look of thermoplastic gears. Often gears are subject to a stall torque that is considerably higher than the standard loading torque. If plastic gears are run at high speeds, they become vulnerable to hysteresis heating which may get so serious that the gears melt.

There are several methods to reducing this kind of heating. The preferred way is to lessen the peak tension by increasing tooth-root region available for the required torque transmission. Another approach is to lessen stress in the teeth by increasing the apparatus diameter.

Using stiffer components, a material that exhibits much less hysteresis, can also prolong the operational existence of plastic-type material gears. To increase a plastic’s stiffness, the crystallinity levels of crystalline plastics such as acetal and nylon could be increased by processing techniques that boost the plastic’s stiffness by 25 to 50%.

The most effective approach to improving stiffness is by using fillers, especially glass fiber. Adding glass fibers increases stiffness by 500% to at least one 1,000%. Using fillers does have a drawback, though. Unfilled plastics have fatigue endurances an order of magnitude higher than those of metals; adding fillers decreases this advantage. So engineers who would like to use fillers should look at the trade-off between fatigue existence and minimal heat buildup.

Fillers, however, do provide another advantage in the ability of plastic gears to resist hysteresis failure. Fillers can increase temperature conductivity. This can help remove heat from the peak stress region at the base of the gear tooth and helps dissipate heat. Heat removal may be the additional controllable general element that can improve resistance to hysteresis failure.

The surrounding medium, whether air or liquid, includes a substantial influence on cooling prices in plastic gears. If a fluid such as an oil bath surrounds a gear instead of air, heat transfer from the apparatus to the oils is usually 10 times that of the heat transfer from a plastic gear to surroundings. Agitating the oil or air also improves heat transfer by a factor of 10. If the cooling medium-again, air or oil-is definitely cooled by a heat exchanger or through style, heat transfer increases a lot more.