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Polymer Gear Development to Improve Efficiency and NVH Performance of an Engine Mass Balance System
Technical Paper
2011-01-0405
ISSN: 0148-7191, e-ISSN: 2688-3627
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English
Abstract
A joint development program between Metaldyne and Victrex Polymer Solutions was established with the goal of developing a cost effective net shape injection molded gear that provides improvements in NVH (Noise Vibration and Harshness) and operating efficiency over conventional high quality iron gears. A detailed DOE (Design of Experiments) evaluating NVH performance of machined gears was performed in a calibrated NVH test cell. Variables in the DOE included material, gear geometry and backlash variation. The DOE showed the PEEK material gears had different geometric sensitivities, such as helix angle effects, on NVH performance. The results of the DOE were then used to develop an optimal injection molded PEEK polymer gear design. A production quality injection molding gear tool was constructed. Net shape production quality PEEK polymer gears were injection molded and the gears were evaluated in a current production mass balance unit for NVH, mechanical efficiency and durability. The study shows when compared to the baseline gears a net shape injection molded PEEK polymer gear provides a 3db noise reduction, as much as 9% reduction in power consumption, a 69% mass reduction and meets the application durability requirements.
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Authors
Citation
Ferfecki, F. and Hale, A., "Polymer Gear Development to Improve Efficiency and NVH Performance of an Engine Mass Balance System," SAE Technical Paper 2011-01-0405, 2011, https://doi.org/10.4271/2011-01-0405.Also In
References
- Metaldyne Internal Test Report TR4694 “Machined PEEK Transfer Gear NVH Study” March 13 2007
- Metaldyne Internal Test Report TR4856 “Molded PEEK Transfer Gear NVH Study” June 28 2007
- Metaldyne Internal Test Report TR4925 “PEEK 450G Transfer Gear Durability” September 21 2007
- Metaldyne Internal Test Report TRQ001047 “5 degree Helix PEEK 450G Transfer Gear Durability” April 22 2008
- Metaldyne Internal Test Report TR5113 “PEEK on PEEK 5 Degree Helix Transfer Gear NVH” June 2 2008