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制造过程中可实现精度的基础上定义部件的允许偏差，从而保证产品在整个生命周期内的功能，并使具有成本效益的生产成为可能。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-结构偏差也会对构件的性能产生强烈的影响。因此，在项目的第一阶段，确定了制造工艺对塑料/钢齿轮副形状和结构偏差的影响及其对磨合行为的影响。原则上，这使得考虑到材料结构方面，可以得出关于优化磨合行为的公差和设计的建议。研究小组第二阶段的目的是将这方面的知识扩展到对操作行为的全面考虑。在子项目中，应全面调查材料结构和尺寸偏差对运行性能的影响。因此，该子项目通过提供部件公差和结构与由此产生的部件行为之间的基本和一般关系，例如关于面向过程的公差所必需的承载能力和耐磨性，为实现研究小组的目标作出了重大贡献。此外，将制定一种确定这些相互关系的有效程序，从而能够根据模型和材料调查来确定操作行为的特征。在与其他分项目的合作下，将制订一种全面和有效的方法，以便能够根据业务需要设计部件和工序以及确定公差。本子项目第二阶段的目标可概括如下：•在公差管理方面，确定和理解几何和形态组件特性对变形行为和不同载荷条件下运行功能的影响。几何偏差的影响，特别是挤压小齿轮的不同表面地形，对塑料-钢副的操作行为已经确定，可以全面描述。•基于材料、模型和部件调查的相关性，特别是通过现场测量技术，开发并验证了一种有效确定和评估操作行为的扩展方法。

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.