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

面向过程的公差管理的目标是在了解制造过程中可达到的精度的基础上定义部件的允许偏差，从而在产品寿命期间保证产品功能，并实现经济高效的生产。在实践中，这种考虑通常限于尺寸、形状和位置偏差。然而，材料结构偏差也对部件性能有很大影响。因此，在项目的第一阶段，确定了制造工艺对形状和结构偏差的影响及其对塑料/钢齿轮副磨合性能的影响。原则上，这使得可以在考虑材料结构方面的情况下，针对优化的磨合行为，得出公差和设计建议。研究小组第二阶段的目标是扩大这方面的知识，全面考虑经营行为。在子项目中，应全面调查材料-结构和尺寸偏差对操作性能的影响。因此，该子项目通过提供部件公差和结构之间的基本和一般关系以及由此产生的部件行为（例如，关于承载能力和磨损承载能力，这是面向过程的公差所必需的），为实现研究组的目标做出了重大贡献。此外，将制定一个有效的程序来确定这些相互关系，这将使人们有可能在模型和材料调查的基础上描述操作行为。将与其他子项目合作，制定一种全面有效的方法，以便能够根据业务要求设计部件和流程以及确定公差。该子项目第二阶段的目标可概括如下：· 在公差管理方面，识别并理解了几何和形态部件属性对不同负载条件下操作中的变形行为和功能性的影响。· 几何偏差的影响，特别是不同的表面形貌的挤出塑料，对塑料-钢对的操作行为已被确定，并可以全面描述。 一个扩展的方法，有效的确定和评估的操作行为，材料，模型和组件的调查，特别是通过现场测量技术的相关性的基础上，已经开发和验证。

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.