Limitations of the Check Calculation for Tooth Deformation of Plastic Gears According to Gear Design Guideline VDI 2736

An in situ gear test rig has been developed at the Institute of Polymer Technology (LKT) to characterize the deformation of plastic gears during operation. It analyses timing differences between following index pulses of rotary encoders on the input and output shaft. This measurement principle enables the continuous measurement of the elastic tooth deformation and permanent deformations and wear at operating speed by switching between a high and low torque. Gear tests using a steel-polybutylene terephthalate (PBT) gear set were performed at different rotational speeds and tooth temperatures to analyze the tooth deformation during operation. The results were compared to the calculated deformation according to gear design guideline VDI 2736. Moreover, the results of the gear tests were correlated with the results of a dynamomechanical analysis (DMA). Both, the DMA and the in situ gear tests show that the effect of temperature on deformation is much higher than the effect of frequency or rotational speed. However, the experimentally measured tooth deformation is significantly higher (up to 50%) than the calculated at lower speed. Thus, the check calculation according to VDI 2736 underestimates the actual tooth deformation at lower speeds. Therefore, the guideline should be adjusted in the future.