Designing a Polymer Gear for Use in the Environment of an Internal Combustion Engine
Much has been written about the advances in polymer gearing over the past few years. After fitful starts in toys and consumer products, the design and quality of these gears have improved dramatically. Materials advances over the past 20 years have been significant as well. This paper describes the methodology of designing a net shape PolyEtherEtherKetone (PEEK) injection molded gear for an automotive mass balance system. The case study referenced (ref 1) shows that, when compared to the high quality ground iron gears in the same system, a net shape injection molded PEEK polymer gear provides a 3db noise reduction, as much as 9% reduction in power consumption, a 69% mass reduction and meets the application durability requirements. The paper describes the design of the injection molded gear’s unique tooth profile, material selection, part design, mold design, and inspection methods. The paper focuses on the differences in gear design and inspection methods between injection molded gears and their metal counterparts.