AVINASH BHARDWAJ ENROLMENT NO: 100520123027 SEMESTER 6 PLASTIC ENGINEERING CIPET AHMEDABAD

Plastic gears developed only in past 50 years from curiosity to industrial mainstay Everyday , they are growing:
more precise more complex in geometry more powerful larger

Because of : High-performance resins long-fiber compounds

Plastic gears employed today in:

Cars Watches Sewing machines Building controls Missiles.

Strongest growth arena : automobiles Even with all the ground theyve gained, their evolution is still far from over.

Higher-end materials like PPS are finding broader use in gear applications like this start-up section of an ignition switch made by Delphi Saginaw Steering Systems.

start-up section of an ignition switch

This is a variable-ratio geared drive used in cranes and theatrical stages provides safetyrelated interruption of mains or control power.(material : acetal)

differential geared drive made by Stromag AG in Germany

A gear is a rotating machine part having cut teeth, or cogs, which mesh with another toothed part in order to transmit torque.

Numerous nonferrous alloys cast irons powder-metallurgy Plastics

Steels are most commonly used because of their high strength-to-weight ratio and low cost. Plastic is commonly used where cost or weight is a concern

Plastics today can replace steel because of properties like,

dirt tolerance low speed meshing the ability to "skip" quite well and the ability to be made with materials not needing additional lubrication

Plastic offers many cost, design, processing, and performance advantages over metal Manufacturers have employed plastic gears for reduce costs in consumer items
copy machines, optical storage devices, VCRs, cheap dynamos, consumer audio equipment, servo motors, and printers

Plastic gears allow 50% to 90% cost reduction versus stamped or machined metal gears because they usually need no secondary finishing. Plastic gears weigh less than metal gears Plastic gears are relatively inert . So they do not corrode in water pumps and chemical plant controls

Plastic gears offer better gear geometries. Internal gears, cluster gears, and worm gears are cheaper to mould in plastics than metals. Plastic gears enable greater load-bearing capacity and more power transfer in a single stage as they can be wider. Plastic gears are quieter because of high precision, novel tooth shapes, and lubricious or flexible materials.

Plastic gears are more forgiving than those made of metal because plastic deflects to absorb impact loads and also better distributes localized loads caused by misalignment and tooth errors. Plastic gears are internally lubricated and thus ideal for computer printers, toys, and other low-load situations where lubricants are excluded. Plastics can be lubricated by grease or oil.

Among the characteristics responsible for the large increase in plastic gear usage, the following are probably the most significant : 1. Cost effectiveness of the injection-molding process. 2. Elimination of machining operations; capability of fabrication with inserts and integral designs. 3. Low density: lightweight, low inertia. 4. Uniformity of parts. 5. Capability to absorb shock and vibration as a result of elastic compliance.

6. Ability to operate with minimum or no lubrication, due to inherent lubricity. 7. Relatively low coefficient of friction. 8. Corrosion-resistance; elimination of plating, or protective coatings. 9. Quietness of operation. 10. Tolerances often less critical than for metal gears, due in part to their greater resilience. 11. Consistency with trend to greater use of plastic housings and other components.

1. Less load-carrying capacity, due to lower maximum allowable stress; the greater compliance of plastic gears may also produce stress concentrations. 2. Plastic gears cannot generally be molded to the same accuracy as high-precision machined metal gears. 3. Plastic gears are subject to greater dimensional instabilities, due to their larger coefficient of thermal expansion and moisture absorption. 4. Reduced ability to operate at elevated temperatures; as an approximate figure, operation is limited to less than 120C. Also, limited cold temperature operations.

5. Initial high mold cost in developing correct tooth form and dimensions. 6. Can be negatively affected by certain chemicals and even some lubricants. 7. Improper molding tools and process can produce residual internal stresses at the tooth roots, resulting in over stressing and/or distortion with aging. 8. Costs of plastics track petrochemical pricing, and thus are more volatile and subject to increases in comparison to metals.

Popular materials for plastic gears are

Acetal resins such as DELRIN*, Duracon M90; Nylon resins such as ZYTEL*, NYLATRON**, MC901 and Acetal copolymers such as CELCON***.

* Registered trademark, E.I. du Pont de Nemours and Co., Wilmington, Delaware, 19898. ** Registered trademark, The Polymer Corporation, P.O. Box 422, Reading, Pennsylvania, 19603. *** Registered trademark, Celanese Corporation, 26 Main St., Chatham, N.J. 07928

Both thermosetting and thermoplastic material are used, with the latter being by far the most prevalent.
Phenolic(thermosetting).
invariably compounded with various fillers such as wood flour, mineral, glass, sisal, chopped cloth, lubricants as PTFE (polytetrafluorethylene) and graphite. generally used in applications requiring stability, when higher temperatures are encountered.

Polyimide (thermoset)
Polyimide is usually 40-65 percent fiber glass reinforced has good strength retention when used at high operating

Nylon( thermoplastic).
Nylon 6,6 Nylon 12 Nylon 6 Some nylons absorb moisture which may cause dimensional instability. may be compounded with various types and amounts of glass reinforcing materials, mineral fillers, and such lubricants as PTFE and MoS2 (molybdenum disulfide).

Acetal (thermoplastic).
lower water absorption rate than nylon and is more stable after molding or machining. used unfilled or filled, with glass and minerals with and without lubricants, such as PTFE and MoS2, as well as one version with fibrous PTFE.

Polycarbonate (thermoplastic).
Used in addition of glass fiber and/or PTFE lubricant is a fine, low shrinkage material Accurate.

Polyester (thermoplastic).
unfilled and with glass fiber, competing with nylon and acetal.

Polyurethane (thermoplastic).
flexible and therefore, has the ability to absorb shock and deaden sound

SAN(Styreneacrylonitrile) (thermoplastic).
stable, low shrinkage material is used in some lightly loaded gear applications.

Polyphenylene Sulfid (thermoplastic).

When compounded with 40 percent glass fiber with or without internal lubricants, it has been found in certain gear applications to have much greater strength, even at elevated temperatures, than most materials previously available.

Polymer Elastomer (thermoplastic).

Polymer elastomer is a newcomer to the gearing field, has excellent sound deadening qualities resistance to flex fatigue resistance to Impact resistance to creep

The physical and mechanical properties of these materials vary with regard to strength, rigidity, dimensional stability, lubrication requirements, moisture absorption, etc. Depend on applications.

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