Predicting Abrasive Wear of Reinforced Thermoplastic Spur Gears

Performance is key to success in many things. Gear applications are no different. 

Envalior introduces a research initiative focused on the predictive modeling of sliding wear in fiber-reinforced thermoplastic spur gears. The study integrates advanced simulation techniques with experimental validation to explore the complex interplay between material behavior, contact pressure, and wear mechanisms. The approach aims to enhance the reliability of wear predictions in polymer gear systems, particularly under dry-running and lubricated conditions.

Stanyl®, the ultimate material for plastic gears

Envalior’s high-performance polyamide, Stanyl® PA46, is widely used in thermoplastic gear applications due to its superior wear resistance and thermal stability. However, translating material properties into accurate wear predictions remains a challenge, especially when simplified tribological tests fail to capture the intricacies of real-world gear operation.

This research addresses the limitations of conventional testing by combining full-scale gear testing with a Disc-to-Disc (D2D) tribological setup. The goal is to develop a robust modeling framework that accounts for fiber orientation, contact pressure, and temperature effects.

Advanced simulation and experimental setups

The study employs a modified version of Archard’s Law, enhanced to reflect pressure-dependent wear behavior. Key components of the methodology include:

• Anisotropic material modeling based on fiber orientation predictions from injection molding simulations.
• Finite Element Analysis (FEA) to simulate gear meshing and contact pressure distribution.
• Hybrid wear factor modeling, integrating empirical data from D2D tests across various conditions.