Multiscale Study of Polymer Gear Failure Under Variable Torque Conditions

Document Type : Research Article

Authors

1 Department of Mechanical Engineering, Technical and Vocational University (TVU), Tehran, Iran

2 Division of Plastics and Composites Engineering, Department of Mechanical Engineering, University of Tabriz, Tabriz, Iran

Abstract

The failure of polymer gears is strongly affected by applied torque and surface temperature. Higher torque increases contact stress and temperature, accelerating gear degradation. This study investigates failure mechanisms through multiscale analysis under five torque levels (6, 8, 10, 12, and 14 N·m) using polyoxymethylene (POM), a common polymer for plastic gears. Gear surface temperature was monitored online during tests. Failure mechanisms were examined on both macroscopic and microscopic scales. Macroscopically, surface characteristics were analyzed, while scanning electron microscopy (SEM) provided insights into microscopic wear patterns. Results revealed that increasing torque from 6 to 14 N·m raised surface temperature by up to 98%, attributed to combined mechanical and thermal effects. At lower torque levels (6–10 N·m), pitch-line cracks, plastic deformation, and wear were observed. However, at torques above 10 N·m, material flow and adhesive wear became dominant, with severe microscopic material movement linked to POM’s low thermal conductivity.

Keywords

Main Subjects

References

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Amirkabir Journal of Mechanical Engineering
Volume 57, Issue 2
2025
Pages 171-186

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