One fundamental difference between molded plastic gears and metal gears is the difference in manufacturing methods. Almost all metal gears are machined and ground, and molded plastic gears are machined from molds.
(1) One fundamental difference between molded plastic gears and metal gears is the difference in manufacturing methods. Almost all metal gears are machined and ground, and molded plastic gears are machined from molds. With wire cutting, the spur gear cavity can reach an accuracy of 2.5μm. However, since the method is not developed, the cutting error may occur at any position. Therefore, the entire internal gear cavity must be tested, unlike cutting. The machined metal gear only needs to detect several representative teeth. On the other hand, since the shrinkage ratio of each part of the molded plastic gear is different and the modulus value may occur in any part, it is also necessary to detect each part of the gear. The advantage of molded plastic gears is that any special gear can usually be molded as long as it can be drawn in CAD. The challenge is how to measure and adjust the shrinkage anomalies and molding anomalies of molded plastic gears. Metal gears may also benefit from molded plastic gears in terms of the application of full profile inspection technology and the advantages compared to the development method.
(2) Plastic gears and metal gears differ due to different processing methods. The metal gear is cut or ground and is rotary. Therefore, it has high coaxiality and the diameter accuracy is easy to guarantee. It is not necessary to consider shrinkage compensation in manufacturing. The plastic gear is molded, and the coaxiality is difficult to guarantee, but the tooth shape is more accurate than the metal gear, and the precision of the gear cavity of the wire cutting process is higher than that of the gear cavity processed by the rolling electrode.
(3) Plastic gears are inferior to metal gears, but have the advantages of self-lubrication, light weight and low noise that metal gears lack. Large, continuous and repeatable shrinkage characteristics of engineering plastics in the mold cavity need to be considered and compensated for when machining the gears. In general, the diameter tolerance of plastic gears is larger than that of metal gears.
The tolerances and transmission ratios of plastic gears are all based on the structure of metal gears, but these standards are unfair to plastic gears because they do not accurately guess the function and life of plastic gears, even if they are distributed according to resin materials. The plastic properties provided by the manufacturer cannot accurately determine the true parameters of the material when the plastic gear enters or exits at high speed. The properties of traditional plastics are obtained in the long run.
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