Abstract
This study presents comprehensive findings on the tribological and thermal behavior of polymer gears under varying loads and operating conditions. Gear tooth wear-rates and thermal contact behavior were investigated for nylon (PA) and acetal (POM) materials, fabricated using machining (MC). Experimental investigations were performed under loads of 6.5 N m, 8.5 N m, and 9.0 N m, while maintaining a consistent rotational velocity of 1500 rpm. The wear-rates and surface temperatures were systematically monitored utilizing a linear variable differential transformer (LVDT) with a precision of 0.1 µm and a high-resolution thermal imaging apparatus. Results revealed that at 9.0 N m, thermal stabilization reduced wear-rates by 15% compared to 8.5 N m, due to the softened material layer acting as an internal lubricant. Conversely, higher wear-rates at 8.5 N m were attributed to localized debris formation and limited thermal softening. Key findings include the identification of the glass transition temperature of PA at approximately 75 °C and its effect on wear behavior. These insights provide a deeper understanding of polymer gear performance, offering guidance for material selection and operational optimization in high-performance applications.
