Abrasive flow machining applied to plastic gear matrix polishing

Kenda, Jani; Duhovnik, Jože; Tavčar, Jože; Kopač, Janez

doi:10.1007/s00170-013-5461-4

Cited by 49 publications

(15 citation statements)

References 23 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The tool matrix was linearly scaled in all axes for 0.9%. Additional improvements to the gear surface roughness were achieved using tool matrix polishing (Kenda, 2014). Digital microscope (Keyence VHX-200) was used to analyse the failure modes of the polymer gears.…”

Section: Methodsmentioning

confidence: 99%

Accelerated lifetime testing of reinforced polymer gears

Tavčar

Grkman

Duhovnik

2018

JAMDSM

View full text Add to dashboard Cite

The main advantages of polymer gears compared to metal gears are low manufacturing costs for mass production, vibration damping, and there is no need for a lubricant. In the literature and guidelines, the allowable gear endurance limits for bending and contact stresses are mainly given for polyamides (PA) and polyacetals (POM). A large number of suitable polymer gear materials is available, but the standards offer little support for the lifetime calculations of polymer gears from other materials. Therefore, the testing of gear geometry and materials combinations cannot be avoided in the design of an optimal gear drive. However, gear testing is very time-consuming and expensive, especially when testing several different material combinations in different testing conditions. By applying the upgraded accelerated testing procedure, gear test time and costs can decrease significantly. Determination of the gear temperature during meshing is needed for the precise calculation of plastic gears. The presented temperature calculation model is corrected and improved with input parameters, which were determined from the test results. Accelerated tests were conducted on different combinations of reinforced and unreinforced commercially available materials: PA6, PA66, POM and PPS. Glass and carbon fiber were used for reinforcement. The research goal was characterization of different material pairs with the coefficient of friction, time strength, wear, and the failure mechanism in relation to load cycles and load level. The paper's contribution are some general guidelines for selecting polymer material for gears, such as fiber reinforcement improves the allowable stress level at up to a few million load cycles; unreinforced polymers are better for a higher number of load cycles. Also, PTFE -the internal lubricant significantly reduces a coefficient of friction if added to PA polymers, and is less efficient in combination with POM.

show abstract

Section: Methodsmentioning

confidence: 99%

Accelerated lifetime testing of reinforced polymer gears

Tavčar

Grkman

Duhovnik

2018

JAMDSM

View full text Add to dashboard Cite

show abstract

“…The tool matrix was linearly scaled in all axes. Additional improvements to the gear surface roughness were achieved using tool matrix polishing [28].…”

Section: Test Gear Geometry and Selected Materialsmentioning

confidence: 99%

An accelerated multilevel test and design procedure for polymer gears

Pogačnik

Tavčar

2015

Materials & Design (1980-2015)

View full text Add to dashboard Cite

“…Santhosh [18] reviewed several published technical papers on AFM with respect to its abrasive media and applications. Kenda [19], Wang [20], Kar [21], Sankar [22], and Guo [23] studied the rheological properties and the finishing behavior of abrasive medium in AFM through different examples.…”

Section: Introductionmentioning

confidence: 99%

An experimental investigation of abrasive suspension flow machining of injector nozzle based on orthogonal test design

Fang

2020

Int J Adv Manuf Technol

View full text Add to dashboard Cite

The application of abrasive suspension flow machining (ASFM) to grind a diesel engine injector nozzle is discussed in this paper. The purpose is to remove the sharp corners of the spray holes and improve the fuel flow through the injector nozzle. The proposed method adopts one-way flow to grind the spray holes for high-efficiency production. Compared with traditional reciprocating flow grinding methods using abrasive pastes, the viscosity of slurry and abrasive concentration of ASFM are lower, better for more smooth flow. To achieve a good grinding performance, it is important to determine proper viscosity and concentration. For this purpose, a design of experiments (DoE) method is adopted. In this paper, an orthogonal test method is combined with a nonlinear regression method to optimize the process parameters. Through a range analysis on experiment results, the optimal process conditions in terms of the grinding efficiency and the grinding quality are determined. Experiment verifications show that the optimized process parameters can significantly improve the ASFM grinding efficiency and grinding quality.

show abstract

Abrasive flow machining applied to plastic gear matrix polishing

Cited by 49 publications

References 23 publications

Accelerated lifetime testing of reinforced polymer gears

Accelerated lifetime testing of reinforced polymer gears

An accelerated multilevel test and design procedure for polymer gears

An experimental investigation of abrasive suspension flow machining of injector nozzle based on orthogonal test design

Contact Info

Product

Resources

About