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AGMA 920- 01
[Tables or other self--supporting sections may be quoted or extracted. Credit lines should
read: Extracted from AGMA 920--A01, Materials for Plastic Gears, with the permission of
the publisher, the American Gear Manufacturers Association, 1500 King Street, Suite 201,
Alexandria, Virginia 22314.]
Approved October 22, 2000
ABSTRACT
The purpose of this document is to aid the gear designer in understanding the unique physical, mechanical and
thermal behavior of plastic materials. The use of plastic materials for gear applications has grown considerably
due to cost and performance issues. Growing markets include the automotive, business machine, and consumer--related industries. Topics covered include general plastic material behavior, gear operating conditions,
plastic gear manufacturing, tests for gear related material properties, and typical plastic gear materials. There
are no quantitative details on material properties nor any comparative evaluations of plastic types. Such specific information is left to be provided by material suppliers and gear manufacturers.
Published by
ii
AGMA 920--A01
Contents
Page
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
1
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2
General nature of plastic materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3
Gear operating conditions and related material properties . . . . . . . . . . . . . . . . . 3
4
Gear manufacturing and related material properties . . . . . . . . . . . . . . . . . . . . . . 8
5
Tests for gear related material properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6
General description of plastic materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7
Plastic materials widely used for gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8
Material selection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figures
1a
1b
2
3
4
5
6
7
Tables
1
2
3
iii
AGMA 920--A01
Foreword
[The foreword, footnotes and annexes, if any, in this document are provided for
informational purposes only and are not to be construed as a part of AGMA Information
Sheet 920--A01, Materials for Plastic Gears.]
Plastic materials differ considerably from metals in performance and processing. Many of
the important differences, especially those that are critical to gear applications, are not
widely recognized. This is partly because many plastic materials specialists are not familiar
with gear requirements. Similarly, many gear specialists are not familiar with plastic
material characteristics. Hence the need for reference material which will help bridge these
gaps.
The AGMA Plastics Gearing Committee has brought together technical representatives
from plastic material suppliers, gear manufacturers and designers. This document
represents their efforts to further this exchange of information. It will not supply answers to
many of the questions that arise in the application of plastic materials to gears, but it should
encourage inquiry and information exchange.
One issue that requires special attention is the availability of plastic material properties in
the form most suitable for plastic gear design. This includes properties that are counterparts
of those used in the design of metal gears, and those that are special to plastic materials in
these applications. To a very large extent, plastic gear designers have access only to
property data taken from ASTM tests as reported by material suppliers even though such
tests were created to meet other objectives. It was therefore judged essential to include
brief descriptions of these tests supplemented by comments on any limitations of such test
data when applied to gears. Various industry initiatives are now underway to develop gear
specific property data, which will in time supplement the information provided here.
The first draft of AGMA 920--A01 was made in 1993. It was approved by the AGMA
membership in October, 2000, and approved for publication by the Technical Division
Executive Committee on October 22, 2000.
Suggestions for improvement of this document will be welcome. They should be sent to the
American Gear Manufacturers Association, 1500 King Street, Suite 201, Alexandria,
Virginia 22314.
iv
AGMA 920--A01
ACTIVE MEMBERS
M.A. Bennick . . .
R.M. Casavant . .
D.S. Ellis . . . . . . .
T. Grula . . . . . . . .
J.W. Kelley . . . . .
R.R. Kuhr . . . . . .
I. Laskin . . . . . . . .
D. Michael . . . . . .
A. Milano . . . . . . .
S.D. Pierson . . . .
RTP Company
GW Plastics, Inc.
ABA--PGT, Inc.
DuPont Company
Shell Development Company
Enplas, Inc.
Consultant
CEI
Seitz Corporation
ABA--PGT, Inc.
M. Schireson . . .
D. Sheridan . . . . .
L. Siders . . . . . . .
Z.P. Smith . . . . . .
P.A. Spaziani . . .
M. Thompson . . .
A.B. Ulrich . . . . . .
J.H. Winzeler . . .
P. Wyluda . . . . . .
G. Martello . . . . .
H.S. Oh . . . . . . . .
M. Oliveto . . . . . .
A.J. Padden . . . .
K. Price . . . . . . . .
J. Rees . . . . . . . .
C. Reese . . . . . . .
E. Reiter . . . . . . .
J.T. Rill . . . . . . . . .
J. Seitz . . . . . . . . .
L.J. Smith . . . . . .
R.E. Smith . . . . . .
P.A Tuschak . . . .
B. Ulissi . . . . . . . .
G.J. Verros . . . . .
M. Wilkinson . . . .
BF Goodrich
Siebe Environmental Controls
DSM Engineering Plastics, Inc.
SPM Minneapolis
Eastman Kodak Company
ATS Precision Component Div.
SPM Minneapolis
ATS Precision Component Div.
Black & Decker, Inc.
Seitz Corporation
Consultant
R.E. Smith & Co., Inc.
E.I. DuPont deNemours & Co.
DuPont Performance Lubricants
Consultant
GW Plastics, Inc.
ASSOCIATE MEMBERS
M.K. Anwar . . . . .
M. Aube . . . . . . . .
D.E. Bailey . . . . .
J. Barger . . . . . . .
T. Barry . . . . . . . .
D. Blakley . . . . . .
M. Bogle . . . . . . .
B. Butsch . . . . . . .
D. Castor . . . . . . .
P. Davoli . . . . . . .
E. Dornan . . . . . .
G.C. Hesser . . . .
A.H. LaFord . . . .
J. Lay . . . . . . . . . .
R.B. Lewis . . . . . .
A. Luscher . . . . . .
T. Mardis . . . . . . .
Globe Motors
GW Plastics, Inc.
Rochester Gear, Inc.
D.I.G.I.T., Inc.
Phillips--Moldex Company
Axxicon Components
Poly Hi Solidur Co.
Lexmark International, Inc.
Eastman Kodak Company
Politecnico Di Milano
Winzeler Gear
DuPont Company
Static Control Components, Inc.
NYE Lubricants, Inc.
Lewis Research, Inc.
Ohio State University
CEI
1 Scope
This information sheet provides descriptions of
plastic materials commonly used in gearing. It
relates the general properties of these materials to
typical operating conditions of gears. Properties that
relate to the manufacturing processes of machining
and molding are discussed, including the property of
shrink rate in molding. It also describes the types of
tests that are customarily used to obtain published
values of these properties.
It is intended that this information sheet serve only as
an introductory guide to the designer of plastic gears
when it comes to selecting candidate materials. The
designer is advised to look to material suppliers and
plastic gear manufacturers for their expert guidance
on selecting materials for specific applications. It is
also important to recognize that thorough application
testing is often needed to confirm the suitability of a
material choice.
Only a limited number of plastic materials are
mentioned here as commonly used for gears. Gears
have been made from other plastics as well, but
generally because some special material property or
commercial consideration was judged essential to a
particular application. It is also possible that the
suitability of other materials for gears has not yet
been recognized. Furthermore, new plastic materials are continually being developed and some, no
doubt, will prove themselves as important additions
to those discussed in this information sheet.
AGMA 920--A01
AGMA 920--A01
SRupture
Increasing stress
Stress
Strain
Increasing
temperature
0
0
Time
Strain
Figure 2 -- Effect of strain rate and temperature
on stress--strain curves
2.4 Effect of temperature
2.4.1 Strength and deformation
SRupture
Strain
Increasing stress
0
0
Time
Because a higher temperature reduces the resistance to movement of the polymer chains, the
material at high temperatures can be viewed as less
viscous (decrease of the viscous component). This
decrease in the viscous component of polymers at
higher temperatures causes the strength and stiffness properties to decrease with increasing temperatures (see figure 2). Temperature increases of the
polymer at critical locations in gears could result from
friction, hysteresis, or both in combination. This
temperature rise of the gear material at critical
locations could, therefore, reduce the load resisting
capability of the gear. This condition is a significant
factor to consider in gear performance.
2.4.2 Expansion
Plastics have higher thermal expansion rates than
metals. These high rates can be partially offset by
compounding the plastics with various fillers and
reinforcements. Thermal expansion must be considered in those applications in which the gears
apply
in
nearly
103
104
105
No. of cycles
106
107
Increasing stress *
AGMA 920--A01
all
gear
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3.1.2.3 Wear
3.1.4
Mechanical property changes under
operating conditions
--40C
23C
66C
Stress
85C
100C
Strain, %
AGMA 920--A01
Tensile stress
Dry as molded
50% RH
0.5
1.5
Strain, %
2.5
Figure 5 -- Effect of moisture on stress vs. strain for nylon 6--6 (PA 6,6) at 23C
3.1.4.3 Chemical environment
Plastics, in contrast to most metals, are generally
resistant to a broad variety of chemicals. However,
individual plastics may be vulnerable to particular
chemicals. The effect of chemical action is generally
a reduction in fatigue and impact strength and
change in other mechanical properties. See 3.2.6.2.
3.2 Special operating conditions
These conditions are encountered less commonly in
gear applications, but, when they do, they direct
attention to other properties of the plastic material.
3.2.1 Impact loading
In some gear applications, the gears may be subject
to a suddenly applied load which requires the
material to absorb considerable energy associated
with the load. This energy tends to be absorbed
around design features that, because of their
slender shape and reduced size, are most compliant
and develop the highest stresses. The contacting
gear teeth are commonly most vulnerable. Such
loads may appear with sudden starts of the gear train
driver, a sudden change or reversal in the driven
load, or with sudden braking. The energy to be
absorbed is even greater if there has been travel
AGMA 920--A01
AGMA 920--A01
ductile--brittle
transition
temperature
(DBTT)
Decreasing temperature
Figure 6 -- Polymer impact strength as a function of temperature
AGMA 920--A01
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gear design;
10
4.2.1 Moldability
This characteristic of a material relates to how well it
will fill the mold cavity without, at the same time,
flashing into the very fine gaps at the edges of the
cavity. It is primarily determined by the viscosity of
the molten plastic during mold filling. The viscosity
can be altered by changes in the molding process,
for example mold and melt temperatures, but
sometimes only at the expense of the quality of the
molded part. Quality defects from improper process
changes may take the form of voids, sinks, warpage,
and internal stresses. Plastic materials can be
especially sensitive to overheating. Outgassing can
develop from the chemistry of additives such as
toughening agents, flame retardants, and some
internal lubricants.
4.2.2 Shrink rate (shrinkage)
The degree and uniformity of shrinkage of the plastic
material is also a factor in its suitability for a molded
gear application. The shrinkage is determined first
by the molecular structure of the plastic and other
additives. In the molding process, it will also be
influenced by cross sectional area, cooling rate, fiber
orientation, molding temperatures and pressures,
and other processing variables. The predictability
and consistency of the shrinkage is generally more
significant in producing accurate gears than the
magnitude of the shrinkage (or shrink rate).
Shrinkage in gears is not always uniform, as in
photographic size reduction. Molding process and
part design, along with material shrinkage properties, may contribute to this non--uniformity. When
mold gear cavity design inappropriately assumes
that the shrinkage will be purely uniform, the quality
of the molded gear will suffer. The directional
non--uniformity of the shrink rate is also an important
factor as discussed below.
4.2.2.1 Dimensional non--uniformity in gear
diameter
Directional non--uniformity in shrinkage can be a
major factor contributing to eccentric and out--of-round gears, especially in plastics with high aspect
ratio fiber reinforcement. In such materials, differences in both the relative amount and direction of
fiber orientation will lead to different amounts of
shrinkage in the plastics, both radially and axially.
The shrinkage will be reduced in the direction of fiber
orientation. The effect of such directional properties
can sometimes be offset by techniques of mold
AGMA 920--A01
in all directions.
However, for some materials, these directional
effects can be so great that the materials must be
ruled out if a high accuracy gear is required.
4.2.3 Other directional properties
Flow induced orientation can also affect the mechanical, electrical, tribological and thermal properties of
a molded gear. This non--uniformity is generally tied
to flow direction in the filling of the mold cavity and is
most marked in materials with fiber reinforcement.
11
AGMA 920--A01
13 mm
Wc
19
mm
50 mm
76 mm
57 mm
115 mm
Figure 8 -- ASTM D638 Type 1 tensile specimen
12
7 mm
or less
AGMA 920--A01
13
Normalized modulus
AGMA 920--A01
Temperature
Figure 9 -- Typical DMA curves normalized at 23C
5.1.3.3 Details of test
In a DMA test, the test specimen receives a
harmonic excitation at a known frequency and very
small amplitude. In most test equipment, the
harmonic excitation is the displacement and the
resulting force is the measured response. In other
equipment, the reverse is used. The sample is
mounted in a closed chamber with accurate temperature control. The test chamber temperature is
increased at a constant rate during the test. Thus,
data are obtained over a wide range of temperatures, typically from --50C to near the melting point
of the material. Figure 10 illustrates a tensile DMA
geometry with fixed displacement amplitude.
Data obtained from the test are the load amplitude,
displacement amplitude, and frequency at a considerable number of temperatures. The frequency is
often fixed but a number of frequencies may also be
used. Since all materials, and especially plastics,
are viscoelastic, there is a phase shift between the
displacement and the measured load. The phase
shift, , is also recorded either directly but more often
as tan ().
14
(1)
where
E
Apply
harmonic
displacement
AGMA 920--A01
Displacement
Phase
shift
Test
specimen
7
time
Load
7
time
Measured load
15
AGMA 920--A01
Tg
Loss modulus, E
E = |E*| cos ()
tan ()
E = |E*| sin ()
Temperature
Figure 11 -- DMA, amorphous and crystalline polymers
Tg
E = |E*| cos ()
tan ()
Loss modulus, E
E = |E*| sin ()
Temperature
Figure 12 -- DMA, semi--crystalline polymer
16
AGMA 920--A01
17
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50.8 mm
57.2 mm
103.2 mm
18
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19
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Creep modulus
Increasing
stress or strain
Time (hr)
10
100
1000
10 000
Stress
Strain
Figure 14c -- Representations of creep -isochronous stress vs. strain
20
AGMA 920--A01
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23
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5.5.1
Test method for rubber property -durometer hardness -- ASTM D2240
25
AGMA 920--A01
5.5.4 Flammability
AGMA 920--A01
Melt
Crystals
Amorphous
Solid
Figure 16 -- Two dimensional representation of crystalline and amorphous thermoplastics
27
AGMA 920--A01
Modulus
Crystalline (unreinforced)
Tg
Tg
Amorphous (unreinforced)
Tm
Temperature
Figure 17 -- Modulus behavior vs. temperature of crystalline and amorphous resins, neat and glass
fiber reinforced
Figure 17 shows the modulus response for neat
amorphous and crystalline resins, as well as glass
fiber reinforced versions. For both types of polymers, the addition of reinforcing fibers substantially
increases the modulus, yet does not affect the
inherent thermal transition temperature points.
NOTE: Dynamic mechanical analysis (DMA) (see
5.1.3) is an analytical method to determine polymer
property changes as a function of temperature. The
change in modulus characteristics of a plastic material,
as it approaches or exceeds important and unique thermal transitions, can yield important design information
about the load bearing capabilities within the temperature range of operation. These data are more useful to
the design engineer than the commonly cited ASTM
test, deflection temperature under load (DTUL), which
determines at what temperature a standard molded
specimen deflects 0.25 mm.
28
AGMA 920--A01
strength;
6.1.2 Thermosets
--
impact resistance;
--
rigidity (modulus);
--
thermal conductivity;
--
flame retardance;
--
dimensional control;
--
color;
--
heat stability;
--
noise reduction;
--
oxidative stability;
--
U.V. stability;
--
lubricity;
--
wear resistance;
--
processability.
29
AGMA 920--A01
Type
Fillers
Reinforcements
Name
Minerals (mica, talc, carbon
powder, glass beads, etc.)
Organic
Glass fiber
Carbon fiber
Aramid fiber
Percentage
range
5--40
Reason
for use1)
C, DC, E, H
Limiting
factors2)
WM, RI, TW
<1
5--40+
10--40+
5--20
PA, H
H, w
H, E, W
H, ST, W, F
ST
-- -D, WM, TW
C, D, TW
C, d
(Thermoset materials
only)
C, MC, st
C
MC
ST, RI
-- -ST
ST, D, C
w, c
c
C, MC, TW, D, ST, RI
Organic fabrics
Lubricants
Impact modifiers
Others
PTFE
PFPE
Silicone
Graphite
Molybdenum disulfide
TPU
Color
Processing aids
Stabilizers (UV/Heat)
Flame retardance
1--20
<1
1--4
5--10
2--5
5--20
<2
F, W
F, W, PA
F, W
F, W
W
II
-- -MC
-- --- --
NOTES:
1)
C -- reduce cost; F -- reduce friction; H -- improve heat resistance; II -- improve impact resistance; ST -- improve
strength; W -- reduce wear; PA -- processing aide; E -- electrical; DC -- dimensional control (shrinkage).
2)
C -- high cost; D -- distortion molding; MC -- molding condition; ST -- strength reduction; TW -- tool wear -- RI -reduce impact resistance; WM -- wear of gear mate.
NOTE: Lower case letter imply a lesser effect.
30
AGMA 920--A01
7.2 Thermosets
Only a small number of thermoset plastics have
been used for gears to any substantial degree. The
properties of most of this class of plastics are
generally less favorable to gears than to other
applications. The different type of processing is
often an additional obstacle to broader use for gears.
31
AGMA 920--A01
environment;
--
mechanical;
--
regulatory;
--
manufacturing;
--
cost.
due
to
thermal
The common environmental conditions are described below. Each description consists of a list of
potential sources of the condition followed by a list of
possible effects on the plastic material properties.
The material selection process will consist of
identifying those materials that offer adequate
performance under all of the conditions that apply.
8.1.1 Temperature range (ambient, heat from
gear action)
The temperatures experienced in each application
will be based on one or more of the following:
-- ambient temperature (outside of gear unit)
during operation;
-- heating due to adjacent sources of heat, such
as the motor, other electrical components, or
process heaters;
-- heating of the gears during operation due to
some combination of friction and hysteresis
effects;
32
dimensional change;
dimensional changes.
8.1.4 Lubrication
The lubricant, either an oil or grease, may act as one
form of chemical exposure. If the type of the
lubricant is dictated by conditions necessary to other
aspects of the application, the plastic gear material
must be selected with appropriate chemical resistance. With less restrictive conditions on the choice
of lubricant, it may be possible to select a type which
is chemically compatible with an otherwise preferred
plastic material.
8.1.5 Abrasive particles
The source of such particles may be:
-- external dust entering into an inadequately
sealed gear case;
--
AGMA 920--A01
ozone.
33
AGMA 920--A01
--
load magnitude;
--
--
AGMA 920--A01
8.4.1 Molding
If the material must be processed at higher temperatures, the complexity and cost of the mold will be
increased. Plastics with abrasive additions will
require more frequent replacement of mold components and, often, molding machining components as
well. Some other additives may produce a tough
adhering film on mold surfaces, increasing mold
maintenance and reducing mold life.
8.4.2 Machining
Producing gears by machining introduces its own
restrictions on material selection. These restrictions
may be the commercial availability of some materials. They may also come from practical considerations in the machining process.
35
AGMA 920--A01
AGMA 920--A01
37
AGMA 920--A01
38
AGMA 920--A00
Bibliography
The following documents are either referenced in the text of AGMA 920--A00, Materials for Plastic Gears or
indicated for additional information.
ANSI/AGMA 1006--A97, Tooth Proportions for Plastic Gears
ASTM D256--97, Standard Test Methods for Determining the Izod Pendulum Impact Resistance of
Plastics
ASTM D792--98, Standard Test Methods for Density and Specific Gravity (Relative Density) of Plastics
by Displacement
ASTM D1822--99, Standard Test Method for Tensile--Impact Energy to Break Plastics and Electrical
Insulating Materials
ASTM D2863--97, Standard Test Method for Measuring the Minimum Oxygen Concentration to
Support Candle--Like Combustion of Plastics (Oxygen Index)
ASTM D3702--94 (1999), Standard Test Method for
Wear Rate and Coefficient of Friction of Materials in
Self--Lubricated Rubbing Contact Using a Thrust
Washer Testing Machine
ASTM D3801--00, Standard Test Method for Measuring the Comparative Burning Characteristics of
Solid Plastics in a Vertical Position
ASTM D4065--95, Standard Practice for Determining and Reporting Dynamic Mechanical Properties
of Plastics
ASTM D4092--96, Standard Terminology Relating
to Dynamic Mechanical Measurements on Plastics
ASTM D5023--99, Standard Test Method for Measuring the Dynamic Mechanical Properties of Plastics Using Three Point Bending
ASTM D5024--95a, Standard Test Method for
Measuring the Dynamic Mechanical Properties of
Plastics in Compression
ASTM D785--98, Standard Test Method for Rockwell Hardness of Plastics and Electrical Insulating
Materials
ASTM D790--99, Standard Test Methods for Flexural Properties of Unreinforced and Reinforced
Plastics and Electrical Insulating Materials
ASTM D5279--99, Standard Test Method for Measuring the Dynamic Mechanical Properties of Plastics in Torsion
39
AGMA 920--A00
ASTM D5418--99, Standard Test Method for Measuring the Dynamic Mechanical Properties of Plastics Using a Dual Cantilever Beam
ASTM E662--97, Standard Test Method for Specific
Optical Density of Smoke Generated by Solid
Materials
ASTM F433, Standard Practice for Evaluating
Thermal Conductivity of Gasket Materials
IEC 60695--2--10, Fire hazard testing -- Part 2--10:
Glowing/hot--wire based test methods -- Glow wire
apparatus and common test procedure
IEC 60695--2--11, Fire hazard testing -- Part 2--11:
Glowing/hot--wire based test methods -- Glow--wire
flammability test method for end products
IEC 60695--2--12, Fire hazard testing -- Part 2--12:
Glowing/hot--wire based test methods -- Glow--wire
flammability test method for materials
IEC 60695--2--13, Fire hazard testing -- Part 2--13:
Flowing/hot--wire based test methods -- Glow--wire
ignitability test method for materials
ISO 10350--1:1998, Plastics -- Acquisition and
presentation of comparable single--point data -- Part
1: Moulded plastics
ISO 10993--1:1997, Biological evaluation of
medical devices -- Part 1: Evaluation and testing
ISO 10993--2:1992, Biological evaluation of
medical devices -- Part 2: Animal welfare
requirements
ISO 10993--3:1992, Biological evaluation of
medical devices -- Part 3: Tests for genotoxicity,
carcinogenicity and reproductive toxicity
ISO 10993--4:1992, Biological evaluation of
medical devices -- Part 4: Selection of tests for
interactions with blood
ISO 10993--5:1999, Biological evaluation of
medical devices -- Part 5: Tests for in vitro
cytotoxicity
ISO 10993--6:1994, Biological evaluation of
medical devices -- Part 6: Tests for local effects after
implantation
ISO 10993--7:1995, Biological evaluation of
medical devices -- Part 7: Ethylene oxide
sterilization residuals
40
PUBLISHED BY
AMERICAN GEAR MANUFACTURERS ASSOCIATION
1500 KING STREET, ALEXANDRIA, VIRGINIA 22314