Gear TiconaGearDesignPPT AM 1211 Gear-007R1

Design and
Development of
Precision Plastic Gear
Transmissions
David Sheridan
Sr. Design Engineer
December 2011
1
2011 Ticona Gears Webinar Gears-007r1 EN 12/11
Section Outline
1. Why Ticona for plastic gears
2. Why plastic for gears
3. Design and engineering
4. Specifications
5. Prototypes and inspection
6. Testing and validation
7. Production
We Offer You a Broad Product Portfolio

Celcon /
Hostaform
Acetal Copolymers
(POM)
Celanex
Thermoplastic
Polyester (PBT)
Impet
Thermoplastic
Polyester (PET)
Vandar
Thermoplastic
Polyester Alloy (PBT)
Backed up by
A responsive service network
Skilled application
development and technical

support
Across the US, Europe and
the Asia-Pacific region
Global Service And Support

3
Riteflex
Thermoplastic Polyester
Elastomer (TPC-ET)
Celstran
Long Fiber
Reinforced
Thermoplastics (LFRT)
Fortron
Polyphenylene Sulfide
(PPS)
Vectra
Liquid Crystal Polymer
(LCP)
Ticona and the Gear Industry

Ticonas been a leader in plastic gear
technology for over 40 years

1961: Celcon POM commercialized
Gears were among early applications
1969: First Plastic Gear Design manual

Among founding members of AGMA
Plastic Gearing Committee
With UTS (TK Solver) co-developed
Plastic Gear Design software based
on Ticona gear design manual
Developed PGEAR test machine
First plastic material supplier to
exhibit at AGMA Gear Expo
Ticonas Gear Development Support

Our global technical centers support
customers through all stages of

application development
Gear analysis
Material selection
Gear material testing
Prototype tool design
Injection molding trials
Failure analysis
Staff training from gear experts
Comprehensive gear material and
design information
5
Section Outline
4. Specifications
7. Production
Plastic vs. Metal Gears

Plastic Advantages
Lower cost
Injection molding vs. machining
Especially for large quantities
As-molded, no finishing
Greater design flexibility

Parts consolidation
Molded-in features
Allow other gear geometries
Easy to mold, difficult to
machine, e.g., internal and
cluster gears
Less noise
Lower modulus
Do not transmit sound
Greater tooth deflection
increases load sharing and
reduces transmission error
effects
Light weight, low inertia

Reduce dynamic loading
and noise
Plastic vs. Metal Gears

Plastic Advantages
Inherent lubricity
Do not need lubrication in
many low-load applications
Internal lubricants
For applications that
cannot use external
lubricants
Computer printers
Motorized toys
Chemical and corrosion
resistance
External lubricants
Grease
Oil
Water
Lawn sprinklers
Water meters
Shower heads
Section Outline
4. Specifications
7. Production
The Plastic Gear Development Team

Project Engineer
Molder
Tool
Builder
Manufacturing
Engineer
Gear Engineer
Purchasing
Material
Supplier
Quality Control
Engineer
Plastics Engineer
10
Plastic Gear Development

Identify Application Voice of the Customer (VOC)
Define Operating Requirements
Prime mover
Torque and speed

Inertia, natural freq.
Load(s)
Torque and speed
Special conditions
Inertia, natural freq.
Duty cycle
Life
Physical limits
Ratio
Precision
Efficiency
Lubrication
Environment
Temperature
Chemical exposure
Moisture exposure
Test requirements
Other
Anticipate Future Applications

11
Select Overall Transmission Geometry

From requirements
Minimum weight?
Minimum size?
Good plastic designs may use more
gears with split power path
Carefully consider added features
Runout
Distortion
Shafting and bearings
Precision
Efficiency
Housing considerations
Stiffness
Tolerances
12
Relative Gear Train Size

15:1 Reduction
13
Single Reduction
100%
Double Reduction
Single Branch
40%
Double Reduction
Double Branch
25%
2 Stage Planetary
9.5%
Preliminary Gear Sizing

Select materials
Select preliminary gear geometry
Number of teeth
Size (pitch or module)
Profile (tooth proportions)
Nominal ambient conditions
Simple load analysis
K-factor
Unit load
14
Select Materials
Suit operating environment
Temperature range
Dimensional behavior
Property behavior
Chemical environment
Dimensional behavior
Property behavior
Appropriate property mix
Fatigue
Stiffness
Impact
Creep
Interaction with other components

Friction
Wear
15
Precision Engineering Components
Dimensional Requirements
(i.e., Tolerances)
MUST Equal Manufacturing
Capabilities
16
Concentricity Tolerances
for Unfilled Acetal
AGMA vs. SPI*
12
Concentricity (10-3 in.)
SPI Commercial Tolerances

10
8
SPI Fine Tolerances
AGMA
Q7
12 DP
24DP
Q10
2
01
17
12 DP
24 DP
3
Gear Diameter (in.)
4
*The Society of the Plastics Industry
Gear Engineers Job

To develop gear tooth geometry and assembly
specifications that will produce gears that function
satisfactorily under all operating conditions and
across the entire range of manufacturing tolerances
and environmental influences on dimensions.
18
One Approach
Use analytical models for gear
tooth geometry and load analysis

Include all possible tolerances and
environmental influences on
dimensions in effective operating
center distance
Design Perfect gear geometries
Develop gear geometry at tight
mesh, maximum material
condition
Re-analyze at open mesh,
minimum material condition
Analyze worst load condition
19
Determine Production Tolerances

For All Components
Gears
Outer diameter and tolerance
Root diameter and tolerance
Tooth thickness and tolerance
Tooth tip radius and tolerance
Accuracy grade
Total composite
tolerance (TCT)
20
Total Composite Error, TCE

Housing
Mounting center distance and tolerance
21

Shafts, bushings, bearings
Diameters and tolerance
Maximum and minimum radial play

Concentricity (TIR)
22
Maximum radial play
Minimum radial play
Maximum bushing diameter

Minimum shaft diameter
Minimum bushing diameter

Maximum shaft diameter
Develop at Tight Mesh,

Maximum Material Condition
Maximum material condition
Maximum tooth thickness

Maximum outside diameter
Maximum root diameter
Minimum tooth tip radius
Select minimum effective
operating center distance
23
Optimize geometry
Maximize contact ratio
Minimize root clearance
Tip interference?
Minimize backlash
Minimize specific sliding
Load analysis at temperature

Minimize or balance stresses
Excessive tooth deflection?
Tip relief?
Determine Effective Operating

Center Distance Range
Assembled center distance range
Mounting center distance and
tolerance
Bushings, bearings, and shafts
Maximum and minimum radial play
Runout (TIR)
Gears
Total composite tolerances (Accuracy
grades)
Environmental effects
Environmental conditions
Temperature range
Humidity range
Chemical exposure?
Dimensional response
between housing and gears

Thermal response (CLTE)
Moisture or chemical response
Examine when
humid-hot
humid-cold
dry-hot
dry-cold
Determine extreme CD range
and conditions
24
Analyze at Open Mesh,

Minimum Material Condition
Minimum material condition
Minimum tooth thickness

Minimum outside diameter
Minimum root diameter
Maximum tooth tip radius
Maximum effective
operating center distance
Check geometry
Contact ratio > 1?
If not, go back to beginning,
Select new diametral pitch or
module
Change tooth proportions
Renegotiate tolerances
Load analysis at
temperature
Load capacity
Excessive tooth deflection?
Tip relief?
25
Analyze Other Load Conditions

Tight mesh condition is often
hot and humid

Open mesh condition is often
cold and dry
But worst load condition
Open mesh - minimum load
sharing
Hot and humid - minimum
material properties
Transient conditions
Cold housing and hot gears
Hot housing and cold gears
26
Finally
Iterate until all of the above works
Design time cheap
Changes during/after development costly ($ and )
Computer programs are necessary

Analytical programs preferred
Graphical programs often
cause problems
Write specifications
27
Section Outline
4. Specifications
7. Production
28
Specifications
Plastic gear transmissions require significant engineering effort.
Components
Gears
Housings
Shafts
Bearings
Variations
Manufacturing tolerances
Operating conditions
(i.e., temperature, moisture)
Dimensions
Material properties
Making certain the resulting design intent is specified clearly,

accurately, and precisely to the gear manufacturer is essential to
ensuring performance, cost, and delivery requirements are met.
29
Specifications
30
Specifications
31
Section Outline
4. Specifications
7. Production
32
High-Precision Gear Molding
Accurately predicting and

consistently controlling
(precision) shrinkage.
33
The Controlling Principle

Shrinkage is only affected by materials:
Orientation (polymer and reinforcement)
Temperature
Pressure
Almost everything can have an effect on at least
one of these three things and will effect

shrinkage.
34
Prototypes
Verification of part and material performance
Verification of manufacturing capabilities with dimensional
control
Represent production as mush as possible
Mold
Molding conditions
Mold material
# cavities, runners, gates, etc.
Cooling channels
Molder
Molding machine
Barrel size
residence time
Injection rate
Clamp tonnage
Temperatures
Mold
Melt
Cycle profile
Injection speed
Hold time & pressure
Cooling time
Screw RPM & back

pressure
Identical to Production
35
Accuracy vs. Precision

The Target Analogy
36
High Accuracy
High Precision
Low Precision
Low Accuracy
Prototype Mold Development

Precision
Follow material suppliers molding recommendations
Establish appropriate processing window
Maximize material properties
Resist correcting dimensions with extreme
processing conditions
Wide, stable processing window

Minimal variational effects on properties and dimensions
Maximize dimensional stability

Consistent as-molded dimensions
Precision vs. cycle time
Minimize post-molding shrinkage

Mold temperature must exceed operating temperature
Pay now, or pay later!
Design of experiments (DOE)
Stability Equals Precision

37
Prototype Mold Development

Accuracy
Then correct tooling for shrinkage
Cut molds steel safe

Undersized cavities
Oversized cores
Use inserts
Iterate
Measure thoroughly
Make what you designed
Then Correct for Accuracy

38
Plastic Gear Development Cycle

Design & Engineering
Prints & Specifications
Prototype Tool & Parts
Measurement & Inspection
Testing
Production
39
Inspection and Geometry Verification

During development
Elemental inspection (CNC)
Profile error (involute error)

Lead error (helix angle error)
Pitch error (spacing error)
Runout (radial position error)
General inspection
Outside radius
Root radius
Tooth thickness
Measurement over pins or balls
Elemental Inspection for Development

40
Inspection and Geometry Verification

During production
Composite inspection (Double-flank roll checker)
Total composite error (TCE)
Tooth-to-tooth error (TTE)
Runout
Stability Equals Precision

41
Section Outline
4. Specifications
7. Production
42
Testing and Validation

Geometry verification!
Realistic
Properly represents end-use conditions
Continuous testing when end-use is
intermittent
Overheating
No thermal or dimensional recovery
time
Temperature control
Effective
Static loads
Creep and creep rupture
Impact loads
Motor stall load
Motor rotor inertia load
Appropriate
Test procedures often developed for
metal gears
Keep It Real
43
Plastic Gear Development Cycle

Design & Engineering
Prints & Specifications
Prototype Tool & Parts
Measurement & Inspection
Testing
Production
44
Section Outline
4. Specifications
7. Production
45
Production
Utilize prototype knowledge
Minimize deviations
Mold
Mold machine
Molding conditions
Wide, stable process

Maximum material properties
Consistent dimensions
Correct tooling for accuracy

Measure thoroughly
Run capability study
Establish production QC methodology
Produce!
46
David Sheridan
Sr. Design Engineer
D.Sheridan@ticona.com
Product Information
800-833-4882
ProdInfo@ticona.com
www.ticona.com
47
NOTICE TO USERS:
Information is current as of December 2011 and is subject to change
without notice.
The information contained in this publication should not be construed
as a promise or guarantee of specific properties of our products.
Any determination of the suitability of a particular material and part
design for any use contemplated by the user is the sole responsibility of
the user. We strongly recommend that users seek and adhere to the
manufacturers current instructions for handling each material they use.
Any existing intellectual property rights must be observed.
2011 Ticona. Except as otherwise noted, trademarks are owned by Ticona or its affiliates.
48

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Design and

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

We Offer You a Broad Product Portfolio

development and technical

the Asia-Pacific region

Global Service And Support

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

Ticona and the Gear Industry

technology for over 40 years

1969: First Plastic Gear Design manual

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

Ticonas Gear Development Support

customers through all stages of

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

Plastic vs. Metal Gears

Greater design flexibility

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

Light weight, low inertia

Plastic vs. Metal Gears

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

Chemical and corrosion

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

The Plastic Gear Development Team

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

Plastic Gear Development

Torque and speed

Anticipate Future Applications

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

Select Overall Transmission Geometry

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

Relative Gear Train Size

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

Preliminary Gear Sizing

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

Appropriate property mix

Interaction with other components

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

Precision Engineering Components

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

SPI Commercial Tolerances

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

Gear Engineers Job

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

tooth geometry and load analysis

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

Determine Production Tolerances

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

Total Composite Error, TCE

Determine Production Tolerances

Mounting center distance and tolerance

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

Determine Production Tolerances

Maximum and minimum radial play

Maximum radial play

Minimum radial play

Maximum bushing diameter

Minimum bushing diameter

2011 Ticona Gears Webinar Gears-007r1 EN 12/11

Develop at Tight Mesh,

Maximum tooth thickness

Select minimum effective

operating center distance