Design & Development of Precision Plastic Gear Transmissions
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1 Design & Development of Precision Plastic Gear Transmissions David Sheridan Senior Design Engineer TICONA Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
2 Overview Methodical and rational procedure for designing and developing high-precision injection-molded plastic gear transmissions that function satisfactorily across the entire range of manufacturing tolerances and operating conditions. Calculations to examine the effects of tolerances and environmental influences on gear geometry, operating center distance, and gear performance Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
3 Outline 1. Why plastics for gears 2. Gear types and arrangements for plastics 3. Design and engineering 4. Specifications 5. Prototype parts and mold development 6. Measurement and inspection 7. Testing and validation 8. Production molding Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
4 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 Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
5 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 Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
6 Outline 1. Why plastics for gears 2. Gear types and arrangements for plastics 3. Design and engineering 4. Specifications 5. Prototype parts and mold development 6. Measurement and inspection 7. Testing and validation 8. Production molding Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
7 Involute Gearing Involute Curve Taut String Base Circle Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
8 Involute Gearing Advantages of Involute Gear Teeth Provide constant angular velocity (or ratio) between two gears conjugate action Conjugate action is independent of changes in center distance (CD) design flexibility insensitive to manufacturing tolerances, material expansion and contraction Manufacturing ease and accuracy with basic rack Conjugate Action Independent of CD Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
9 Gear Types and Arrangements Parallel Axis Spur Helical External or Internal Non-Parallel Intersecting Axis Bevel, On-Center Face, On-Center Non-Intersecting Axis Worms Bevel, Off-Center Face, Off-Center Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
10 Straight Bevel Gears Dudley Critical on Mounting and Alignment Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
11 Face Gears Not critical on center distance Not critical on axial position Dudley Recommended for Plastics Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
12 Worm Gearing Characteristics High ratio Low part count Low cost Low noise Low capacity Types of Worm Gears Involute worm (crossed-helical) Worm thread profile straight in axial plane Worm thread profile straight in normal plane Worm produced by conical mill or grinding wheel with straight sides These are NOT interchangeable! Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
13 Worm Gearing Singleenveloping Doubleenveloping Semienveloping Cylindrical Dudley Critical on Mounting and Alignment Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
14 Crossed-Helical Involute Gears Not critical on center distance Not critical on axial position Theoretical POINT contact Useful for low power low cost low noise Recommended for Plastic Worm Gearing Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
15 Gear Types and Arrangements Parallel Axis Spur Helical External or Internal Epicyclics Non-Parallel Intersecting Axis Bevel, On-Center Face, On-Center Non-Intersecting Axis Worms Bevel, Off-Center Face, Off-Center Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
16 Epicyclic Drives Epicyclic Arrangements Simple epicyclics Multi-stage epicyclics Compound epicyclics Coupled epicyclics Fixed differentials Characteristics Large reductions High power density Small space Split power path Simple Epicyclics Planetary Star Sun Input Output Simple Planetary Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf Dudley
17 Relative Gear Train Size 15:1 Reduction Single Reduction 100% ( f d 2 ) Double Reduction Single Branch 40% Double Reduction Double Branch 25% 2-Stage Planetary 9.5% Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
18 Outline 1. Why plastics for gears 2. Gear types and arrangements for plastics 3. Design and engineering 4. Specifications 5. Prototype parts and mold development 6. Measurement and inspection 7. Testing and validation 8. Production molding Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
19 Gear Noise Influence of Gear Quality 56.8dB 61.1dB 58.3dB 68.5dB Low Noise Gears High Large Noise Gears Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
20 The Plastic Gear Development Team Project Engineer Molder Manufacturing Engineer Tool Builder Gear Engineer Purchasing Material Supplier Plastics Engineer Quality Control Engineer Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
21 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 Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf Gears-007r1 EN 12/11
22 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 Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
23 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 Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf For more information see ANSI/AGMA 1106-A97, Tooth Proportions for Plastic Gears
24 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 For more information see AGMA 920-A01, Materials for Plastic Gears Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
25 Determine Production Tolerances Gears Diameters and tolerances Tooth thickness and tolerance Tip radius and tolerance Accuracy grade Housing Center distance and tolerance Shafts, bearings, and bushings Diameters and tolerances Runout Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
26 Precision Engineering Components Dimensional Requirements (i.e., Tolerances) MUST Equal Manufacturing Capabilities Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf Gears-007r1 EN 12/11
27 Preliminary Cost Estimate Overall geometry Components sized Materials selected Tolerances Cost Estimate Alternative concepts Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
28 Decision Point Evaluate changes Refine cost estimate Commit tooling Gear Design Begins Engineering data for materials Analyze theoretical gear tooth geometry Extreme geometry conditions Extreme load conditions Iterate Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
29 Plastic Properties & Dimensions Mechanical properties vary Temperature Moisture Obtain strength & modulus data for load analysis At operating conditions Dimensions vary Temperature Thermal expansion > metals (x10) Moisture Obtain material data for dimensional stability considerations Thermal expansion Moisture expansion Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
30 About Gear Tooth Geometry and Assembly Always perfect in analytical models Always perfect in CAD models Always imperfect in production Operating environment alters geometry Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
31 Gear Engineer s 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 Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf Gears-007r1 EN 12/11
32 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 Re-analyze at open mesh Analyze worst load condition Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
33 Develop at Tight Mesh Condition Maximum Material Condition Maximum tooth thickness Minimum tip radius External gear Maximum outer diameter Maximum root diameter Internal gear Minimum inner diameter Minimum root diameter Select Tight Center Distance External gear set Minimum effective operating center distance Internal gear set Maximum effective operating center distance Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
34 Develop at Tight Mesh Condition 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? Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
35 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 Gears Total composite tolerances (Accuracy grades) Environmental effects Environmental conditions Temperature range Moisture exposure Dimensional response between housing and gears Thermal response (CLTE) Moisture response Examine when Cold-Dry Cold-Wet Hot-Dry Hot-Wet Determine extreme CD range and conditions Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
36 Assembled Center Distance Range Mounting Center Distance Housing Center distance and tolerance C M C Mmin C Mmax Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
37 Assembled Center Distance Range Mounting Center Distance Shafts, bushings, bearings Diameters and tolerance Maximum and minimum radial play Maximum radial play Minimum radial play Maximum bushing diameter Minimum shaft diameter Minimum bushing diameter Maximum shaft diameter Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
38 Assembled Center Distance Range Mounting Center Distance Shafts, bushings, bearings Concentricity or runout Nominal Radius Runout Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
39 Assembled Center Distance Range Mounting Center Distance Gears Accuracy grade Total composite tolerance (TCT) Total Composite Error, TCE Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
40 Assembled Center Distance Range External Gear Set C Amin C Mmin (BRP (BRO Pmin P BRP Gmin BRO )/2 G )/2 C Amax C Mmax (BRP (BRO Pmax P BRP Gmax BRO G )/2 )/2 TCT P TCT G C C A M BRO BRP TCT Assembled center distance Mounting center distance Bearing runout Bearing radial play Total composite tolerance Subscripts: A - assembled M - mounting P - pinion G - gear Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
41 Assembled Center Distance Range Internal Gear Set C Amin C Mmin (BRP (BRO Pmax P BRP Gmax BRO G )/2 )/2 (TCT P TCT G ) C Amax C Mmax (BRP Pmin (BRO P BRP Gmin BRO )/2 G )/2 C C A M BRO BRP TCT Assembled center distance Mounting center distance Bearing runout Bearing radial play Total composite tolerance Subscripts: A - assembled M - mounting P - pinion G - gear Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
42 Operating Center Distance Range Environmental Effects Add change in center distance due to temperature and moisture effects to assembled center distance range Examine at temperature and moisture extremes Cold-dry C O min C Amin C Cold-wet Hot-dry Hot-wet C O max C Amax C Find overall maximum and minimum operating center distance Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
43 Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf RH T T d RH T T d C P M P P M M P G M G G M M G ) ( 2 ) ( 2 Operating Center Distance Range Environmental Effects - External gear set moisture expansion of Coefficient expansion thermal of Coefficient Operating pitch diameter Change in relative humidity Change in temperature T distance Change in center C d RH A A G G A P P A M M RH RH RH T T T T T T T T T
44 Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf Operating Center Distance Range Environmental Effects - Internal gear set moisture expansion of Coefficient expansion thermal of Coefficient Operating pitch diameter Change in relative humidity Change in temperature T distance Change in center C d RH A A G G A P P A M M RH RH RH T T T T T T T T T RH T T d RH T T d C P M P P M M P G M G G M M G ) ( 2 ) ( 2
45 Analyze at Open Mesh Condition Minimum Material Condition Minimum tooth thickness Maximum tip radius External gear Minimum outer diameter Minimum root diameter Internal gear Maximum inner diameter Maximum root diameter Open Center Distance External gear set Maximum effective operating center distance Internal gear set Minimum effective operating center distance Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
46 Analyze at Open Mesh Condition 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? Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
47 Analyze Other Load Conditions Tight mesh condition is often hot and moist Open mesh condition is often cold and dry But worst load condition Open mesh - minimum load sharing Hot and moist - minimum material properties Transient conditions Cold housing and hot gears Hot housing and cold gears Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
48 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 Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
49 Outline 1. Why plastics for gears 2. Gear types and arrangements for plastics 3. Design and engineering 4. Specifications 5. Prototype parts and mold development 6. Measurement and inspection 7. Testing and validation 8. Production molding Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
50 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 Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
51 Specifications For more information see AGMA 909-A06, Specifications for Molded Plastic Gears Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
52 Specifications For more information see AGMA 909-A06, Specifications for Molded Plastic Gears Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
53 Outline 1. Why plastics for gears 2. Gear types and arrangements for plastics 3. Design and engineering 4. Specifications 5. Prototype parts and mold development 6. Measurement and inspection 7. Testing and validation 8. Production molding Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
54 High-Precision Gear Molding Accurately predicting and consistently controlling (precision) shrinkage Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf Gears-007r1 EN 12/11
55 The Controlling Principle Shrinkage is only affected by material s: Orientation (polymer and reinforcement) Temperature Pressure Almost everything can have an effect on at least one of these three things and will effect shrinkage Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
56 Accuracy vs. Precision The Target Analogy High Accuracy Low Precision High Precision Low Accuracy Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
57 Precision Material Crystalline resins vs. amorphous resins Shrinkage data Fiber reinforcement Viscosity Part Geometry Wall thicknesses Features/ribs/holes/cams/etc. Fillets inside corners Gate(s) Mold Tolerances Cavitation Cooling Process Temperatures Pressures Cycle time Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
58 Precision Geometry Web Off-Center Web Centered m = 1.0 mm; z = 28; = 20 ; b = 15 mm; Hostaform C Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
59 Precision Ribs 6 Ribs 12 Ribs No Ribs m = 1.0 mm; z = 28; = 20 ; b = 15 mm; Hostaform C Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
60 Precision Gates Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
61 Precision Gates Filling Roundness Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
62 Precision Gates Filling Roundness Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
63 Precision Mold Cooling Bad Better Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
64 Precision Mold Cooling Best Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
65 Prototyping 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 Identical to Production Temperatures Mold Melt Cycle profile Injection speed Hold time & pressure Cooling time Screw RPM & back pressure Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
66 Prototype Mold Development Precision Follow material supplier s 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) Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf Stability Equals Precision
67 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 Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
68 Outline 1. Why plastics for gears 2. Gear types and arrangements for plastics 3. Design and engineering 4. Specifications 5. Prototype parts and mold development 6. Measurement and inspection 7. Testing and validation 8. Production molding Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
69 Plastic Gear Development Cycle Design & Engineering Prints & Specifications Prototype Tool & Parts Measurement & Inspection Testing Production Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
70 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 Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
71 Inspection and Geometry Verification During production Composite inspection (Double-flank roll checker) Total composite error (TCE) Tooth-to-tooth error (TTE) Runout Composite Inspection for QC Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
72 Outline 1. Why plastics for gears 2. Gear types and arrangements for plastics 3. Design and engineering 4. Specifications 5. Prototype parts and mold development 6. Measurement and inspection 7. Testing and validation 8. Production molding Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
73 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 Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf Keep It Real
74 Plastic Gear Development Cycle Design & Engineering Prints & Specifications Prototype Tool & Parts Measurement & Inspection Testing Production Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
75 Outline 1. Why plastics for gears 2. Gear types and arrangements for plastics 3. Design and engineering 4. Specifications 5. Prototype parts and mold development 6. Measurement and inspection 7. Testing and validation 8. Production molding Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
76 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 Make what you designed and verified Run capability study Establish production QC methodology Produce! Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
77 Thank You Questions? Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
78 David Sheridan Sr. Design Engineer Product Information Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
79 NOTICE TO USERS: Information is current as of February 2012 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 manufacturer s current instructions for handling each material they use. Any existing intellectual property rights must be observed Ticona. Except as otherwise noted, trademarks are owned by Ticona or its affiliates Ticona Gears Webinar Gear_DesignPPT_AM_0212_016.pdf
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