Sofia Martinez
Plastic gears are becoming an increasingly popular alternative to metal gears in car transmissions. They offer several advantages over their metal counterparts, including reduced friction losses, lower weight, and improved noise reduction. Plastic gears are also more durable and resistant to corrosion and oxidation, making them ideal for gearboxes in various industries, including automotive, marine, and oil rigs. In addition, plastic gears can eliminate the extensive reworking associated with metal gears and provide cost savings. However, the choice of resin for plastic gears requires careful consideration to ensure the desired performance and quality. While plastic gears offer many benefits, they may not be suitable for all applications, and metal gears continue to be used in certain contexts, such as high-torque situations.
| Characteristics | Values |
|---|---|
| Plastic gear applications | Washer transmission, motorized car seats, printers, toys, car transmissions, turbines, power transmission, gearboxes, marine parts, oil rigs, drill presses, transmissions and reducers |
| Plastic gear advantages | Lightweight, cost-efficient, less noisy, lower friction losses, less horsepower wasted as heat, high resistance to mechanical and tribological stress, no corrosion or oxidation, more durable, better performance, self-lubricating, fewer parts required |
| Plastic gear considerations | Careful selection of resin and lubricants is required to ensure quality and performance |
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What You'll Learn
Plastic gears are more durable and reliable than metal gears
Plastic gears are also more cost-effective than metal gears. They are easier to mould, which means you can create more complex designs with precision and accuracy. This reduces the cost of production. Plastic gears are also self-lubricating, which means they can be used in gear trains where the use of grease must be avoided, such as in printers or toys. They are also quieter than metal gears, which can help to reduce noise in appliances.
Plastic gears are more reliable when engineers account for material properties and manufacturing processes during the design. They are also highly resistant to corrosion, making them ideal for applications involving exposure to chemicals or marine environments. They perform exceptionally well in low-load and low-speed transmission systems.
However, it is important to note that plastic gears have lower strength than metal gears and may not be suitable for applications that require the transfer of high torque or sustained heavy loads, such as industrial machinery or vehicles. The choice between metal and plastic gears depends on the specific requirements of the application.
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Plastic gears are lightweight, sturdy, and cost-effective
Plastic gears are used in some cars, particularly in automatic transmissions and parking lock systems. They are not as strong as metal gears, but they offer several advantages that make them ideal for certain applications.
Plastic gears are highly lightweight, which is a crucial factor in many engineering designs, as it allows for greater ease of movement and less energy expenditure. This quality is especially beneficial in automatic transmissions, where the gears need to shift quickly and smoothly.
In addition to being lightweight, plastic gears are also known for their sturdiness and durability. While they may not match the strength of metal gears, they are still able to withstand significant stress and strain without failing. This makes them a reliable choice for automotive applications, where durability is essential.
Another key advantage of plastic gears is their cost-effectiveness. Plastic gears are generally cheaper to produce than metal gears, making them a more economical option for manufacturers. This cost-effectiveness, combined with their lightweight and sturdy nature, makes plastic gears an attractive choice for car transmissions, as it allows for a balance between performance and budget.
Furthermore, plastic gears produce less noise and vibration than their metal counterparts, resulting in a smoother and quieter ride for the vehicle occupants. This is especially beneficial in electric vehicles, where noise reduction is a key focus area. The excellent lubricity of plastic gears also contributes to their overall performance and longevity.
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Plastic gears are used for noise reduction
Plastic gears are increasingly being used in car transmissions. They are a replacement for metal gears and offer several advantages. One of the key advantages of plastic gears is noise reduction.
Plastic gears are much quieter than their metal counterparts because the teeth of plastic gears can deform, compensating for any misalignments in the rotation. They also have the ability to absorb vibrations due to the intrinsic nature of technopolymers and plastics. This ability to dampen noise and reduce the transmission of vibrations is a highly desirable quality in gears.
The design of plastic gears is critical to achieving quietness. It is important to ensure continuity of transmission, with gradual engagement and disengagement of the teeth to avoid shocks or vibrations. Increasing the average number of contact teeth during rotation results in a more uniform distribution of contact forces, reducing noise. The specific design of the teeth is also important, with the involute tooth profile being well-suited for uniform motion.
The choice of resin is another factor that influences noise levels. Inexpensive commodity resins may not possess the necessary characteristics such as fatigue life, temperature resistance, and dimensional stability. However, engineering resins like acetal copolymer offer superior performance, consistent melt viscosity, and accurate molding, contributing to quieter gear operation.
Lubrication also plays a role in noise reduction. While unlubricated plastic gears can have internal lubricants like PTFE, silicone, or graphite, lubricated gears have lower coefficients of friction. Oil bath or grease lubrication can further enhance the performance of plastic gears, allowing for smoother operation and reduced noise.
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Plastic gears are used in mass-balance transmissions
Plastic gears are now being used in mass-balance transmissions for the first time. Evonik has developed a PEEK moulding compound (polyetheretherketone) with good tribological properties and high durability for use in the harsh environment of an internal combustion engine to replace metal gears. Mass balancers ensure the smooth running of an internal combustion engine by reducing the vibrations caused by the pistons on surrounding structures.
Mass balancer gears come into contact with engine oils and are therefore exposed to maximum temperatures of up to 130°C. Until now, only metal gears have been used in this environment. With Vestakeep PEEK 5000 G, Evonik offers a suitable material with high resistance and high performance to replace these metal gears. The series component is manufactured by IMS Gear SE and is used by Mercedes-Benz in various models.
Plastic gears offer several advantages over conventional metal gears. They have lower friction losses, are significantly quieter, and have a lower mass moment of inertia, which saves energy. They are manufactured by injection moulding and eliminate the extensive reworking that was previously necessary when using metal. They also have high temperature, chemical resistance, and high ductility, making them suitable for lightweight construction applications.
The choice of resin is critical in plastic gear design. Commodity resins generally lack the fatigue life, temperature resistance, lubricant resistance, and dimensional stability required for quality plastic gears. However, engineering resins can provide the necessary performance for working gear trains, with consistent melt viscosity, additive concentrations, and other qualities essential for consistent, accurate molding.
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Plastic gears are self-lubricating
Plastic gears are used in car transmissions to replace metal gears. They are used in mass-balance transmissions to ensure the smooth running of an internal combustion engine by reducing the vibrations caused by the pistons on surrounding structures. Plastic gears are also used in transmissions to save weight, reduce noise, and improve efficiency.
The choice of lubricant for plastic gears is critical, as it must be compatible with the specific plastic material. Incompatible lubricants can cause stress cracking and failure of the part. Lubricants with solid additives, such as graphite or molybdenum disulfide (moly), should be avoided when dealing with plastic gears as they can penetrate and weaken the material. On the other hand, PTFE solid additives can be useful for lowering startup friction or providing dry lubrication.
Mineral-oil-based lubricants are generally good candidates for lubricating plastic gears as they do not attack most plastic materials. However, as operating speeds, temperatures, and operation times increase, synthetic lubricants such as hydrocarbon (PAO) types are preferred. These synthetic lubricants offer long-term lubrication over a wider temperature range and are compatible with most plastics.
It is important to test the compatibility of the lubricant with the plastic gear material under anticipated loads, speeds, and environments. Manufacturers typically set limits on how much change is allowed in the plastic's physical properties after exposure to the lubricant, which is usually around 7 to 10%. By carefully selecting the right lubricant and verifying its compatibility, the performance and lifespan of plastic gears in car transmissions can be optimized.
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Frequently asked questions
Yes, some car transmissions do use plastic gears. Plastic gears are lighter, cheaper, and quieter than their metal counterparts, and they are also more resistant to mechanical and tribological stress.
Plastic gears are a way for mechanical engineers to cut drive costs, weight, noise, and wear. They also allow for smaller, more efficient transmissions and innovative gear designs.
Plastic gears are made from engineering polymers, such as fiberglass-reinforced acetal copolymer, and are manufactured through injection moulding.
Plastic gears are durable and have been used in mass-balance transmissions. They are also resistant to oils and greases, although some lubricants can cause issues with plastic gears.
Yes, modern cars such as the 2006 Mazda 3 2.0L manual have been known to use plastic gears. Plastic gears are also used by Mercedes-Benz in various models.
