Analysis of performance-related, process related structure and shape deviations of plastic gears for application related design

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The goal of process-oriented tolerance management is to define permissible deviations of components on the basis of knowledge about the achievable accuracies in manufacturing processes in such a way that the product function is guaranteed during the product lifetime and cost-effective production is made possible. In practice, this consideration is often limited to dimensional, shape and position deviations. However, material-structural deviations also have a strong influence on the component behaviour. Therefore, in the first phase of the project, the influence of the manufacturing process on the shape and structure deviations and their effect on the running-in behaviour of plastic/steel gear pairs was determined. In principle, this made it possible to derive recommendations for their tolerance and design with regard to optimised running-in behaviour, taking into account material-structural aspects. The aim of the second phase of the research group is to extend this knowledge with regard to a comprehensive consideration of the operating behaviour. In the subproject the influence of material-structural and dimensional deviations on the operating behaviour shall be investigated comprehensively. The subproject therefore contributes substantially to the achievement of the objectives in the research group by providing the fundamental and general relationships between component tolerances and structures and the resulting component behaviour, e.g. with regard to load-bearing capacity and wear-bearing capacity, which are necessary for process-oriented tolerance. In addition, an efficient procedure for determining these interrelationships will be developed, which will make it possible to characterize the operating behaviour on the basis of model and material investigations. In cooperation with the other subprojects, a comprehensive and efficient methodology will be developed to enable the design of components and processes as well as the definition of tolerances in line with operational requirements. The objectives of the second phase for this subproject can be summarized as follows: • The influences of geometric and morphological component properties on the deformation behaviour and the functionality in operation under varied load conditions are identified and understood with regard to tolerance management.• The effects of geometric deviations, in particular different surface topographies of extruded pinions, on the operating behaviour of plastic-steel pairs have been determined and can be described comprehensively.• An extended methodology for the efficient determination and assessment of the operating behaviour, based on the correlation of material, model and component investigations, in particular by means of in situ measurement technology, has been developed and validated.