{"title":"Wear characteristics of 3D-printed spur gears: material type and design parameters effects","authors":"Oğuz Doğan, Muhammed Safa Kamer","doi":"10.1007/s13726-024-01442-2","DOIUrl":null,"url":null,"abstract":"<div><p>Additive manufacturing (AM) has revolutionized the production of complex geometries, enabling the fabrication of components that are difficult or impossible to achieve with traditional manufacturing methods. This research investigates the wear characteristics of polymer gears produced by AM, mainly focusing on asymmetric gears that present unique challenges in conventional machining. A custom-designed gear wear test rig was developed to experimentally examine the wear performance of gears made from five different polymer materials. Additionally, the effects of drive side pressure angles (DSPAs) of 20°, 25°, 30°, and 35° on PLA gears were analyzed. Before wear testing, surface roughness and hardness measurements were conducted. The experiments were performed at two rotational speeds (500 and 1000 rpm) and torque levels ranging from 0.75 to 1.5 Nm. During testing, input and output torque, speed, and temperature were continuously monitored. Quantitative results indicated that the specific wear rate for CPE was the highest at 8.73 [mm<sup>3</sup>/{mm<sup>2</sup>rpm}]10<sup>7</sup>, while PC exhibited the lowest at 1.06, representing an 823.5% difference. Temperature measurements revealed an increase of approximately 25% with higher torque levels. The maximum temperature was measured at 40.5 °C for CPE gears under maximum load and speed conditions. Gear efficiency varied between 0.77 and 0.95, peaking at 0.95 for PC gears under high speed and torque conditions. Furthermore, increasing the DSPA from 20° to 35° resulted in a nearly 60% reduction in specific wear rate. This research addresses limitations in prior studies that often focused on individual materials without systematic analysis of varying DSPA. This study enhances the understanding by providing a comprehensive comparison of wear characteristics of 3D-printed polymer gears, highlighting their potential for lightweight and customizable applications across multiple materials and different DSPAs.</p><h3>Graphical abstract</h3>\n<div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":601,"journal":{"name":"Iranian Polymer Journal","volume":"34 9","pages":"1399 - 1413"},"PeriodicalIF":2.8000,"publicationDate":"2025-01-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Iranian Polymer Journal","FirstCategoryId":"92","ListUrlMain":"https://link.springer.com/article/10.1007/s13726-024-01442-2","RegionNum":3,"RegionCategory":"化学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q3","JCRName":"POLYMER SCIENCE","Score":null,"Total":0}
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Abstract
Additive manufacturing (AM) has revolutionized the production of complex geometries, enabling the fabrication of components that are difficult or impossible to achieve with traditional manufacturing methods. This research investigates the wear characteristics of polymer gears produced by AM, mainly focusing on asymmetric gears that present unique challenges in conventional machining. A custom-designed gear wear test rig was developed to experimentally examine the wear performance of gears made from five different polymer materials. Additionally, the effects of drive side pressure angles (DSPAs) of 20°, 25°, 30°, and 35° on PLA gears were analyzed. Before wear testing, surface roughness and hardness measurements were conducted. The experiments were performed at two rotational speeds (500 and 1000 rpm) and torque levels ranging from 0.75 to 1.5 Nm. During testing, input and output torque, speed, and temperature were continuously monitored. Quantitative results indicated that the specific wear rate for CPE was the highest at 8.73 [mm3/{mm2rpm}]107, while PC exhibited the lowest at 1.06, representing an 823.5% difference. Temperature measurements revealed an increase of approximately 25% with higher torque levels. The maximum temperature was measured at 40.5 °C for CPE gears under maximum load and speed conditions. Gear efficiency varied between 0.77 and 0.95, peaking at 0.95 for PC gears under high speed and torque conditions. Furthermore, increasing the DSPA from 20° to 35° resulted in a nearly 60% reduction in specific wear rate. This research addresses limitations in prior studies that often focused on individual materials without systematic analysis of varying DSPA. This study enhances the understanding by providing a comprehensive comparison of wear characteristics of 3D-printed polymer gears, highlighting their potential for lightweight and customizable applications across multiple materials and different DSPAs.
期刊介绍：
Iranian Polymer Journal, a monthly peer-reviewed international journal, provides a continuous forum for the dissemination of the original research and latest advances made in science and technology of polymers, covering diverse areas of polymer synthesis, characterization, polymer physics, rubber, plastics and composites, processing and engineering, biopolymers, drug delivery systems and natural polymers to meet specific applications. Also contributions from nano-related fields are regarded especially important for its versatility in modern scientific development.
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