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Transmission Efficiency of Functionally Graded Material Based HDPE Spur Gears
Available online at www.sciencedirect.com
ScienceDirect Materials Today: Proceedings 18 (2019) 4893–4900
www.materialstoday.com/proceedings
ICMPC-2019
Transmission Efficiency of Functionally Graded Material Based HDPE Spur Gears Akant Kumar Singha*, Siddharthab, Sanjay Yadava, Prashant Kumar Singhb a b
Department of Mechanical Engineering, I.T.S Engineering College, Greater Noida (UP), 201308, India
Department of Mechanical Engineering, National Institute of Technology Hamirpur (HP), 177005, India
Abstract Polymer gears are replacing the metal gears in various applications due to some of their inherent properties. Polymer gears have lower inertia, less weight and operate much quieter in comparison to metal gears. In this work, glass fiber reinforced functionally graded material based High-Density Polyethylene (HDPE) gears is fabricated using injection molding machine for the investigation of transmission efficiency. Glass fiber filled HDPE materials in the punch are rotated at 1800 rpm for 2 min. for the gradation of the fibers. Homogeneous and neat HDPE gears are also fabricated for comparative study. Polymer gears are running at different speed (600, 800, 1000 and 1200 rpm) and torque (0.8, 1.2, 1.6 and 2 Nm) to investigate the transmission efficiency. Gears are operated for 1.2×105 cycles. The experiments are carried out using a power absorption type polymer gear test rig. It is concluded from this work that transmission efficiency of these polymer gears is significantly affected by torque. Speed has less significant effect on transmission efficiency of polymer gears. © 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019 Keywords: Polymer gears; Polymer gear test rig; DMA; Transmission efficiency
1.
Introduction Acetal and nylon are the most commonly material used to fabricate polymer gear. Polymer gear has the advantage over metal gear in term of noise generation, light in weight, low coefficient of friction and low cost. Polymer gears have positioned themselves as an effective alternate of metal gears. They are suitable for precision type applications to transfer the motion and power. Transmission efficiency is an important parameter for power and motion transmission applications. The overall mechanical system efficiency in some power transmission applications is improved by using the plastic gears [1]. *Corresponding author. Tel.: +91-9882443650 E-mail address: [email protected] 2214-7853 © 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019
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A.K. Singh et al./ Materials Today: Proceedings 18 (2019) 4893–4900
Plastic gears are used in various applications now a day. However, the transmission efficiency of polymer gears has not been investigated much so far. Walton et al. [2, 3] observed that speed and loads are the key factors that significantly affect the transmission efficiency of polymer gears. They investigated the effect of different materials and geometries on the transmission efficiency of polymer gear pairs. Many researchers are working on polymer gears since last decade [4]. Senthilvelan and Gnanamoorthy [5] investigated the efficiency of polymer gears and found that carbon fibre filled composite gear performed better than neat gears due to its enhanced gear tooth stiffness and thermal characteristics. Transmission efficiency of polymer gears is also improved with the addition of nano-clay particles [6]. Transmission efficiency of polymer gears is improved about 2% by using compressed air cooling at the mating surface of master and test gears [7]. Rayudu and Nagarajan [8] studied the effect of gear wear and tooth deformation on the transmission efficiency of plastic gear. Luscher et al. [9] studied the transmission error and geometry of polyketone gears in which transmission efficiency and effect of packing pressure on gear run out is studied. Mertens and Senthilvelan [10] investigated the surface durability of injection-moulded carbon nanotube–polypropylene spur gears and found that inclusion of carbon nanotube improved the efficiency of plastic gears. Experimental and numerical evaluation of transmission characteristics of polymer spur gears are done by Kodeeswaran et al. [11] Wear ant thermal resistance of polymer gear tooth is increased with the reinforcement of fibers inpolymer gear material [12-14]. However, fiber reinforced composite gears also has better transmission efficiency [2, 5]. Damping capability of polymer gears is reduced with the reinforcement of glass fibers and noise emission is also increased [15]. Singh and Siddhartha [16] fabricated the functionally graded materials (FGMs) gears through a novel fabrication technique. The transmission efficiency of FGM gears are found better than the conventional polymer gears. Transmission efficiency has been investigated for different material based polymer gears. However, authors found that transmission efficiency has not been investigated for FGM based HDPE spur gears. Therefore, the focus of this investigation is to develop homogeneous and FGM based HDPE gears and compare their transmission efficiency. 2.
Materials and Methodology
2.1 Gear Fabrication Polymer gears are fabricated using injection molding process. HDPE filled with 30 wt% of glass fibers are used to fabricate homogeneous and FGM gears. Unfilled and glass fiber filled HDPE materials are heated at 60 ̊ C and 70 ̊ C, respectively in a dryer for 4 hours to remove the moisture. Gears are fabricated at the injection pressure of 60 MP. FGM gear is fabricated by rotating the punch at 1800 rpm for 2 minutes. Injection molded gears are shown in Fig. 1 (a-c).
Fig. 1 Injection molded polymer gears; (a) Unfilled HDPE gear, (b) Homogeneous gear, (c) FGM gear
A.K. Singh et al./ Materials Today: Proceedings 18 (2019) 4893–4900
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2.2 Polymer Gear Test Rig A gear test rig (CM-9108) has been used for the testing of the polymer gears. This test rig is fabricated by the DUCOM Instruments, India. Fig. 2 shows a complete arrangement of gear test rig. Each polymer gear meshes with a metal gear having same design specifications. The torque acting on both the gears (polymer and metal) is measured by torque sensors with an accuracy of ± 0.2%. The temperature were continuously measure with the help of a noncontact type infrared sensor (make: OMEGA; model: OS 100EV2 - Series) during experimentation. Sensor is fitted in an acrylic chamber above the mating surface of gears. The sensor can measure the temperature from ambient to 130 °C with least count of 1 °C.
Fig. 2 Polymer gear test rig
2.3 Dynamic mechanical analysis and transmission efficiency Dynamic mechanical analysis (DMA) HDPE is carried out as per ASTM D5023 with the help of a dynamic mechanical analyzer. DMA is performed within the temperature range of 20-140°C and a constant frequency (1 Hz). Transmission efficiency (TE) of unfilled HDPE, homogeneous and FGM gears is examined. Transmission efficiency is calculated using equation 1 by neglecting the powerrloss at couplings and bearings.
TE
3.
Driven gear torque Driver gear torque
(1)
Results and Discussions
3.1 Dynamic Mechanical analysis of gear materials DMA is performed so as to have insight about storage modulus (Eʹ), and damping factor (tan δ). DMA provides the insight about the thermal response of gear materials under the application of cyclic mechanical stresses. Stiffness and impact properties of the gear materials can be predicted by damping behavior of the materials. There are three regions in DMA i.e. glassy region, glass transition region and rubbery region. The temperature at which the rubbery region initiates is known as glass transition temperature (Tg). Figure 3 and 4 shows the effect of temperature on the storage modulus and damping factor unfilled HDPE and 30 wt% of glass fiber filled homogeneous and FGM HDPE materials. It is observed from Figure 3 that the value of storage modulus of ABS, POM and HDPE materials is found to be spacious below glass transition temperature (Tg). It shows a greater contribution of materials characteristics towards the stiffness at low temperature. The integral constituent of polymeric material becomes loose and loses
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A.K. Singh et al./ Materials Today: Proceedings 18 (2019) 4893–4900
their close packing arrangement as the temperature increases and thus results in decreased value of storage modulus in the glass transition region (35–60 ºC). The order of storage modulus of gear materials in the glass transition region is: FGM HDPE > Homogeneous HDPE > unfilled HDPE material. There is no noteworthy change observed in storage modulus for rubbery region. The damping factor (tan δ) represents the ration of loss to the storage in a viscoelastic system or precisely the quantum of internal friction and is a dimensionless number [17]. The highest value of tan δ corresponds to glass transition temperature (GTT). Damping factor of all fabricated composites are shown in Figure 4. The GTT of FGM, Homogeneous and Unfilled HDPE materials are 60 °C, 55 °C and 45 °C respectively. FGM and unfilled HDPE materials have lowest and highest damping factor (tan δ), respectively.
Fig. 3 Storage modulus of gear materials
Fig. 4 Damping factor of gear materials
A.K. Singh et al./ Materials Today: Proceedings 18 (2019) 4893–4900
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3.2 Variation in the transmission efficiency of polymer gears due to speed and torque Gear material plays a significant role in TE of the polymer gears. TE is also affected by speed and the torque acting on the polymer gears. Figure 5(a) and (b) represents the variation in the surface temperature and TE of polymer gears due to the acting torque at the speeds of 600 and 1200 rpm. Figure 5 shows that the surface temperature of gear tooth increases and TE reduces with enhancement of the torque. Flexibility of polymer gear tooth is very sensitive to the gear tooth temperature. Gear tooth surface temperature increases with increase in torque causes teeth deflection. After accomplishment of 1.2 million cycles, some amount of torque on test gear is lost due to deflected gear tooth. Therefore, TE of test gears reduces with enhancement in the torque [3].
Fig. 5(a) TE of the test gears at speed of 600 rpm after 1.2×105 cycle
TE of FGM gear is higher in comparison to homogeneous and unfilled HDPE gears. It happens due to little surface temperature of gear tooth. TE of unfilled HDPE, homogeneous and FGM gears is higher at 600 rpm as compared to 1200 rpm as observed from Figs. 5(a) and (b). High gear tooth surface temperature at 1200 rpm causes less TE for all fabricated gears. Among the unfilled HDPE, homogeneous and FGM gears, FGM gear has highest and unfilled HDPE gear has lowest TE for both constant speeds (600 and 1200 rpm) and at each torque. TE of manufactured gears reduces by 22% for unfilled HDPE gear, 17% for homogeneous gear and 15% for FGM gear when the torque enhances from 0.8 Nm to 2 Nm. Therefore, FGM gear has minimum declination for TE. At the constant speed of 1200 rpm, FGM gears have 5% and 14% higher TE as compared to homogeneous and unfilled HDPE gears, respectively at 2 Nm torque. However, at 600 rpm, ABS gears have higher TE of 7% and 18% as compared to homogeneous and unfilled HDPE gears, respectively at the torque value of 2 Nm. TE of unfilled HDPE, homogeneous and FGM gears is not much affected by variation in speed, as observed in Figure 6. It shows that TE of unfilled HDPE, homogeneous and FGM gears reduces with increase in speed.
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A.K. Singh et al./ Materials Today: Proceedings 18 (2019) 4893–4900
Fig. 5(b) TE of the test gears at 1200 rpm after 1.2×105 cycle
Walton et al. [2, 3] also found the similar results for several other plastic gear materials. TE of unfilled HDPE, homogeneous and FGM gears is higher at the torque of 0.8 Nm in comparison to 2 Nm at each constant speed as evident from Figure 6 (a-b). The reason behind this is that the surface temperature of gears teeth is higher at 2 Nm. TE of unfilled HDPE, homogeneous and FGM gears reduces slightly from 5 to 7 % when the speed increases from 600 rpm to 1200 rpm.
Fig. 6(a) TE of the test gears at 0.8 Nm after completing 2×105 cycle
A.K. Singh et al./ Materials Today: Proceedings 18 (2019) 4893–4900
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Fig. 6(b) TE of the test gears at 2.6 Nm after completing 2×105 cycle
At the constant torque of 0.8 Nm, FGM gears have 7% and 11% higher TE in comparison to homogeneous and unfilled HDPE gears, respectively at 1200 rpm. However, at 2 Nm torque, FGM gears have 4% and 15% higher TE as compared to homogeneous and unfilled HDPE gears, respectively at the speed of 1200 rpm. Therefore, it is clear that performance of FGM gear is superior to homogeneous and unfilled HDPE gears. 4.
Conclusions
The following conclusions are drawn from this study: Glass fiber filled FGM and homogeneous gears are successfully fabricated by injection molding process.Transmission efficiency is significantly affected by torque rather than speed for unfilled, homogeneous and FGM gears.FGM gear has higher TE as compared to homogeneous and unfilled HDPE gears. At 600 rpm, FGM gears have higher TE of 7% and 18% as compared to homogeneous and unfilled HDPE gears, respectively at the torque of 2 Nm. Unfilled HDPE gear has minimum transmission efficiency among all three fabricated gears i.e. 58%. References [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12]
C.E. Adams, Plastic gearing: Selection and application. 2st edn. Marcel Dekker, New York (1986). D. Walton, A.B. Cropper, D.J. Weale, P.K. Meuleman, J. Eng. Tribol. 216 (2002) 75–92. D. Walton, A.B. Cropper, D.J. Weale, P.K. Meuleman, J. Eng. Tribol. 216 (2002) 93–103. A.K. Singh, Siddhartha, P.K. Singh, J. Eng. Tribol. (2017) DOI: 10.1177/1350650117711595. S. Senthilvelan, R. Gnanamoorthy, J. Eng. Tribol. 223 (2009) 925-928. S. Kirupasankar, C. Gurunathan, R. Gnanamoorthy, Maters. Des. 39 (2012) 338–343. A.J. Mertens, S. Senthilvelan, J. Mat. Des. Appl. 230 (2015) 515-525. T. Nagarajan, G.V.N. Rayudu, Proceedings of the 7th World Congress on the Theory of machines and mechanisms Sevilla, Spain (1987) 1335–1338. A. Luscher, D. Houser, C. Snow, J. Injection Molding Technol. 4 (2000) 177–190. A.J. Mertens, S. Senthilvelan, J. Mat. Des. Appl. (2016) DOI:10.1177/1464420716654308. M. Kodeeswaran, R. Suresh, S. Senthilvelan, Int. J. Power Trains 5 (2016) 246-263. C. Gurunathan, S. Kirupasankar, R. Gnanamoorthy, J. Eng. Tribol. 225 (2011) 299-306.
4900 [13] [14] [15] [16] [17] [18]
A.K. Singh et al./ Materials Today: Proceedings 18 (2019) 4893–4900 M. Kurokawa, Y. Uchiyama, T. Iwai, S. Nagai, Wear 254 (2003) 468-473. P.K. Singh, Siddhartha, A.K. Singh, Today. 4 (2017) 1606–1614. S. Senthilvelan, R. Gnanamoorthy, Polym. Test. 25 (2006) 56-62. A.K. Singh, Siddhartha, Poly. Compos. (2017) DOI 10.1002/pc.24682. P.V. Joseph, G. Mathew, K. Joseph, G. Groeninckx, S. Thomas, Compos. A 34 (2003) 275 – 290. S. Kuma, B.K. Satapathy, A. Patnaik, Maters. Des. 32 (2011) 2260 – 2268.
ScienceDirect Materials Today: Proceedings 18 (2019) 4893–4900
www.materialstoday.com/proceedings
ICMPC-2019
Transmission Efficiency of Functionally Graded Material Based HDPE Spur Gears Akant Kumar Singha*, Siddharthab, Sanjay Yadava, Prashant Kumar Singhb a b
Department of Mechanical Engineering, I.T.S Engineering College, Greater Noida (UP), 201308, India
Department of Mechanical Engineering, National Institute of Technology Hamirpur (HP), 177005, India
Abstract Polymer gears are replacing the metal gears in various applications due to some of their inherent properties. Polymer gears have lower inertia, less weight and operate much quieter in comparison to metal gears. In this work, glass fiber reinforced functionally graded material based High-Density Polyethylene (HDPE) gears is fabricated using injection molding machine for the investigation of transmission efficiency. Glass fiber filled HDPE materials in the punch are rotated at 1800 rpm for 2 min. for the gradation of the fibers. Homogeneous and neat HDPE gears are also fabricated for comparative study. Polymer gears are running at different speed (600, 800, 1000 and 1200 rpm) and torque (0.8, 1.2, 1.6 and 2 Nm) to investigate the transmission efficiency. Gears are operated for 1.2×105 cycles. The experiments are carried out using a power absorption type polymer gear test rig. It is concluded from this work that transmission efficiency of these polymer gears is significantly affected by torque. Speed has less significant effect on transmission efficiency of polymer gears. © 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019 Keywords: Polymer gears; Polymer gear test rig; DMA; Transmission efficiency
1.
Introduction Acetal and nylon are the most commonly material used to fabricate polymer gear. Polymer gear has the advantage over metal gear in term of noise generation, light in weight, low coefficient of friction and low cost. Polymer gears have positioned themselves as an effective alternate of metal gears. They are suitable for precision type applications to transfer the motion and power. Transmission efficiency is an important parameter for power and motion transmission applications. The overall mechanical system efficiency in some power transmission applications is improved by using the plastic gears [1]. *Corresponding author. Tel.: +91-9882443650 E-mail address: [email protected] 2214-7853 © 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019
4894
A.K. Singh et al./ Materials Today: Proceedings 18 (2019) 4893–4900
Plastic gears are used in various applications now a day. However, the transmission efficiency of polymer gears has not been investigated much so far. Walton et al. [2, 3] observed that speed and loads are the key factors that significantly affect the transmission efficiency of polymer gears. They investigated the effect of different materials and geometries on the transmission efficiency of polymer gear pairs. Many researchers are working on polymer gears since last decade [4]. Senthilvelan and Gnanamoorthy [5] investigated the efficiency of polymer gears and found that carbon fibre filled composite gear performed better than neat gears due to its enhanced gear tooth stiffness and thermal characteristics. Transmission efficiency of polymer gears is also improved with the addition of nano-clay particles [6]. Transmission efficiency of polymer gears is improved about 2% by using compressed air cooling at the mating surface of master and test gears [7]. Rayudu and Nagarajan [8] studied the effect of gear wear and tooth deformation on the transmission efficiency of plastic gear. Luscher et al. [9] studied the transmission error and geometry of polyketone gears in which transmission efficiency and effect of packing pressure on gear run out is studied. Mertens and Senthilvelan [10] investigated the surface durability of injection-moulded carbon nanotube–polypropylene spur gears and found that inclusion of carbon nanotube improved the efficiency of plastic gears. Experimental and numerical evaluation of transmission characteristics of polymer spur gears are done by Kodeeswaran et al. [11] Wear ant thermal resistance of polymer gear tooth is increased with the reinforcement of fibers inpolymer gear material [12-14]. However, fiber reinforced composite gears also has better transmission efficiency [2, 5]. Damping capability of polymer gears is reduced with the reinforcement of glass fibers and noise emission is also increased [15]. Singh and Siddhartha [16] fabricated the functionally graded materials (FGMs) gears through a novel fabrication technique. The transmission efficiency of FGM gears are found better than the conventional polymer gears. Transmission efficiency has been investigated for different material based polymer gears. However, authors found that transmission efficiency has not been investigated for FGM based HDPE spur gears. Therefore, the focus of this investigation is to develop homogeneous and FGM based HDPE gears and compare their transmission efficiency. 2.
Materials and Methodology
2.1 Gear Fabrication Polymer gears are fabricated using injection molding process. HDPE filled with 30 wt% of glass fibers are used to fabricate homogeneous and FGM gears. Unfilled and glass fiber filled HDPE materials are heated at 60 ̊ C and 70 ̊ C, respectively in a dryer for 4 hours to remove the moisture. Gears are fabricated at the injection pressure of 60 MP. FGM gear is fabricated by rotating the punch at 1800 rpm for 2 minutes. Injection molded gears are shown in Fig. 1 (a-c).
Fig. 1 Injection molded polymer gears; (a) Unfilled HDPE gear, (b) Homogeneous gear, (c) FGM gear
A.K. Singh et al./ Materials Today: Proceedings 18 (2019) 4893–4900
4895
2.2 Polymer Gear Test Rig A gear test rig (CM-9108) has been used for the testing of the polymer gears. This test rig is fabricated by the DUCOM Instruments, India. Fig. 2 shows a complete arrangement of gear test rig. Each polymer gear meshes with a metal gear having same design specifications. The torque acting on both the gears (polymer and metal) is measured by torque sensors with an accuracy of ± 0.2%. The temperature were continuously measure with the help of a noncontact type infrared sensor (make: OMEGA; model: OS 100EV2 - Series) during experimentation. Sensor is fitted in an acrylic chamber above the mating surface of gears. The sensor can measure the temperature from ambient to 130 °C with least count of 1 °C.
Fig. 2 Polymer gear test rig
2.3 Dynamic mechanical analysis and transmission efficiency Dynamic mechanical analysis (DMA) HDPE is carried out as per ASTM D5023 with the help of a dynamic mechanical analyzer. DMA is performed within the temperature range of 20-140°C and a constant frequency (1 Hz). Transmission efficiency (TE) of unfilled HDPE, homogeneous and FGM gears is examined. Transmission efficiency is calculated using equation 1 by neglecting the powerrloss at couplings and bearings.
TE
3.
Driven gear torque Driver gear torque
(1)
Results and Discussions
3.1 Dynamic Mechanical analysis of gear materials DMA is performed so as to have insight about storage modulus (Eʹ), and damping factor (tan δ). DMA provides the insight about the thermal response of gear materials under the application of cyclic mechanical stresses. Stiffness and impact properties of the gear materials can be predicted by damping behavior of the materials. There are three regions in DMA i.e. glassy region, glass transition region and rubbery region. The temperature at which the rubbery region initiates is known as glass transition temperature (Tg). Figure 3 and 4 shows the effect of temperature on the storage modulus and damping factor unfilled HDPE and 30 wt% of glass fiber filled homogeneous and FGM HDPE materials. It is observed from Figure 3 that the value of storage modulus of ABS, POM and HDPE materials is found to be spacious below glass transition temperature (Tg). It shows a greater contribution of materials characteristics towards the stiffness at low temperature. The integral constituent of polymeric material becomes loose and loses
4896
A.K. Singh et al./ Materials Today: Proceedings 18 (2019) 4893–4900
their close packing arrangement as the temperature increases and thus results in decreased value of storage modulus in the glass transition region (35–60 ºC). The order of storage modulus of gear materials in the glass transition region is: FGM HDPE > Homogeneous HDPE > unfilled HDPE material. There is no noteworthy change observed in storage modulus for rubbery region. The damping factor (tan δ) represents the ration of loss to the storage in a viscoelastic system or precisely the quantum of internal friction and is a dimensionless number [17]. The highest value of tan δ corresponds to glass transition temperature (GTT). Damping factor of all fabricated composites are shown in Figure 4. The GTT of FGM, Homogeneous and Unfilled HDPE materials are 60 °C, 55 °C and 45 °C respectively. FGM and unfilled HDPE materials have lowest and highest damping factor (tan δ), respectively.
Fig. 3 Storage modulus of gear materials
Fig. 4 Damping factor of gear materials
A.K. Singh et al./ Materials Today: Proceedings 18 (2019) 4893–4900
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3.2 Variation in the transmission efficiency of polymer gears due to speed and torque Gear material plays a significant role in TE of the polymer gears. TE is also affected by speed and the torque acting on the polymer gears. Figure 5(a) and (b) represents the variation in the surface temperature and TE of polymer gears due to the acting torque at the speeds of 600 and 1200 rpm. Figure 5 shows that the surface temperature of gear tooth increases and TE reduces with enhancement of the torque. Flexibility of polymer gear tooth is very sensitive to the gear tooth temperature. Gear tooth surface temperature increases with increase in torque causes teeth deflection. After accomplishment of 1.2 million cycles, some amount of torque on test gear is lost due to deflected gear tooth. Therefore, TE of test gears reduces with enhancement in the torque [3].
Fig. 5(a) TE of the test gears at speed of 600 rpm after 1.2×105 cycle
TE of FGM gear is higher in comparison to homogeneous and unfilled HDPE gears. It happens due to little surface temperature of gear tooth. TE of unfilled HDPE, homogeneous and FGM gears is higher at 600 rpm as compared to 1200 rpm as observed from Figs. 5(a) and (b). High gear tooth surface temperature at 1200 rpm causes less TE for all fabricated gears. Among the unfilled HDPE, homogeneous and FGM gears, FGM gear has highest and unfilled HDPE gear has lowest TE for both constant speeds (600 and 1200 rpm) and at each torque. TE of manufactured gears reduces by 22% for unfilled HDPE gear, 17% for homogeneous gear and 15% for FGM gear when the torque enhances from 0.8 Nm to 2 Nm. Therefore, FGM gear has minimum declination for TE. At the constant speed of 1200 rpm, FGM gears have 5% and 14% higher TE as compared to homogeneous and unfilled HDPE gears, respectively at 2 Nm torque. However, at 600 rpm, ABS gears have higher TE of 7% and 18% as compared to homogeneous and unfilled HDPE gears, respectively at the torque value of 2 Nm. TE of unfilled HDPE, homogeneous and FGM gears is not much affected by variation in speed, as observed in Figure 6. It shows that TE of unfilled HDPE, homogeneous and FGM gears reduces with increase in speed.
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A.K. Singh et al./ Materials Today: Proceedings 18 (2019) 4893–4900
Fig. 5(b) TE of the test gears at 1200 rpm after 1.2×105 cycle
Walton et al. [2, 3] also found the similar results for several other plastic gear materials. TE of unfilled HDPE, homogeneous and FGM gears is higher at the torque of 0.8 Nm in comparison to 2 Nm at each constant speed as evident from Figure 6 (a-b). The reason behind this is that the surface temperature of gears teeth is higher at 2 Nm. TE of unfilled HDPE, homogeneous and FGM gears reduces slightly from 5 to 7 % when the speed increases from 600 rpm to 1200 rpm.
Fig. 6(a) TE of the test gears at 0.8 Nm after completing 2×105 cycle
A.K. Singh et al./ Materials Today: Proceedings 18 (2019) 4893–4900
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Fig. 6(b) TE of the test gears at 2.6 Nm after completing 2×105 cycle
At the constant torque of 0.8 Nm, FGM gears have 7% and 11% higher TE in comparison to homogeneous and unfilled HDPE gears, respectively at 1200 rpm. However, at 2 Nm torque, FGM gears have 4% and 15% higher TE as compared to homogeneous and unfilled HDPE gears, respectively at the speed of 1200 rpm. Therefore, it is clear that performance of FGM gear is superior to homogeneous and unfilled HDPE gears. 4.
Conclusions
The following conclusions are drawn from this study: Glass fiber filled FGM and homogeneous gears are successfully fabricated by injection molding process.Transmission efficiency is significantly affected by torque rather than speed for unfilled, homogeneous and FGM gears.FGM gear has higher TE as compared to homogeneous and unfilled HDPE gears. At 600 rpm, FGM gears have higher TE of 7% and 18% as compared to homogeneous and unfilled HDPE gears, respectively at the torque of 2 Nm. Unfilled HDPE gear has minimum transmission efficiency among all three fabricated gears i.e. 58%. References [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12]
C.E. Adams, Plastic gearing: Selection and application. 2st edn. Marcel Dekker, New York (1986). D. Walton, A.B. Cropper, D.J. Weale, P.K. Meuleman, J. Eng. Tribol. 216 (2002) 75–92. D. Walton, A.B. Cropper, D.J. Weale, P.K. Meuleman, J. Eng. Tribol. 216 (2002) 93–103. A.K. Singh, Siddhartha, P.K. Singh, J. Eng. Tribol. (2017) DOI: 10.1177/1350650117711595. S. Senthilvelan, R. Gnanamoorthy, J. Eng. Tribol. 223 (2009) 925-928. S. Kirupasankar, C. Gurunathan, R. Gnanamoorthy, Maters. Des. 39 (2012) 338–343. A.J. Mertens, S. Senthilvelan, J. Mat. Des. Appl. 230 (2015) 515-525. T. Nagarajan, G.V.N. Rayudu, Proceedings of the 7th World Congress on the Theory of machines and mechanisms Sevilla, Spain (1987) 1335–1338. A. Luscher, D. Houser, C. Snow, J. Injection Molding Technol. 4 (2000) 177–190. A.J. Mertens, S. Senthilvelan, J. Mat. Des. Appl. (2016) DOI:10.1177/1464420716654308. M. Kodeeswaran, R. Suresh, S. Senthilvelan, Int. J. Power Trains 5 (2016) 246-263. C. Gurunathan, S. Kirupasankar, R. Gnanamoorthy, J. Eng. Tribol. 225 (2011) 299-306.
4900 [13] [14] [15] [16] [17] [18]
A.K. Singh et al./ Materials Today: Proceedings 18 (2019) 4893–4900 M. Kurokawa, Y. Uchiyama, T. Iwai, S. Nagai, Wear 254 (2003) 468-473. P.K. Singh, Siddhartha, A.K. Singh, Today. 4 (2017) 1606–1614. S. Senthilvelan, R. Gnanamoorthy, Polym. Test. 25 (2006) 56-62. A.K. Singh, Siddhartha, Poly. Compos. (2017) DOI 10.1002/pc.24682. P.V. Joseph, G. Mathew, K. Joseph, G. Groeninckx, S. Thomas, Compos. A 34 (2003) 275 – 290. S. Kuma, B.K. Satapathy, A. Patnaik, Maters. Des. 32 (2011) 2260 – 2268.