Efficient gear wheel perspectives made of high-performance plastic
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Plastic Gears from Igus ensure lubricant-free power transmission in countless applications. Because of its special material Composition of base polymers, fibers, fillers and solid lubricants is a Gear Made of Iglidur high-performance polymers, highly wear-resistant. Below we present the New developments before:
Contents
- Plastic bevel gear as a maintenance-free alternative to metal gearwheels
- Polymer gear: printed, milled or injected
- Webinar on gear life calculation
- Configurator for ultra-robust plastic gears
Plastic bevel gear as a maintenance-free alternative to metal gearwheels
05.10.2021 | For the lubricant-free Power Type around the corner, Igus presents its bevel gear portfolio made of two abrasion-resistant and durable high-performance plastics. This gives users a cost-effective and maintenance-free alternative to the metal gearwheel for transmitting forces at an angle of 90 degrees. These Drive Elements are light, inexpensive and completely free of external lubrication.
A bevel gear transmits forces at right angles and takes over, for example Format adjustments in the Food industry, channels out parcels in logistics or is suitable for the flexible and quickly adaptable design of assembly lines in resource requirements and in the Automotive industry.
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The new bevel gears were specially developed for use with low and medium loads. "With Iguform S270 and Igutek P360, we have two materials in our range that have already proven themselves in the gear sector and are also ideal for a bevel gear," says Steffen Schack, Head of the Iglidur gears division at Igus GmbH.
Iguform S270 offers a low coefficient of friction and low moisture absorption. A bevel gear from Igutek P360 on the other hand, it has a very high wear resistance and toughness, which makes the drive element insensitive to impacts. Bevel gears from the tribologically optimized Plastics are light, inexpensive and, in contrast to metal gears, do not require any external lubricant. Maintenance intervals on machines and systems can thus be reduced. The cleanliness and hygiene increase.
Individual special series from injection molding
"With the help of Simulation tools and data from our in-house 3800 square meter test laboratory, we can advise users individually and help them choose the right one Materials and the correct geometry of the teeth from the prototype through to series production," explains Steffen Schack.
Plastic welding | New products, processes, accessories
All bevel gears are available in six different Gear ratios. There are also seven modules for power transmission. If the standard dimensions do not fit, Igus 800 injection molding machines and an in-house toolmaking facility are available for custom-made products: "We can manufacture customer-specific special parts cost-effectively as a series within a few weeks using our new master mold system in the gear sector," explains Steffen Schack.
Igus exhibits at the Hannover Messe 2022, on Automatica 2022 and on AMB 2022.
Polymer gear: printed, milled or injected
04.03.2021 | A plastic gear wheel ensures power transmission in countless devices, from fully automatic coffee machines to actuators. So far, igus has such a gear porfolio from one Semis machined or im 3D pressure manufactured. The Motion Plastics specialist now also offers injection molding especially for the production of wear-resistant and long-lasting gears in large series.
The Plastic gear is enjoying increasing popularity because it does not require a drop of lubricating oil compared to a steel gear. This means that plastic gears are maintenance-free, and that's not all: A plastic gear runs more quietly and is considerably lighter than its steel counterpart.
The injection molded gears recently available from Igus are suitable for a economic production in large series. "With injection molding, the user now has the option of obtaining his gear series from our extensive range of materials," explains Steffen Schack, head of the new Iglidur Gear Wheels division. "We currently offer injection-molded gears made of the materials Xirodur B180 and Iglidur F, each with three hub designs, directly from stock."
xirodur B180 is a wear-resistant endurance runner and dampens vibrations. Igloo F also offers a long service life. In addition, a gear made of this material is also suitable for applications at high temperatures and the black polymer is electrically conductive.
High-performance plastic gear lasts four times longer
The plastic gears developed so far made from Iglidur high-performance polymers have a significantly longer service life than a standard plastic gear. In his laboratory, the plastics specialist puts the injected, printed and milled gears through their paces.
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Tested injected gears made of Xirodur B180 showed a service life four times longer than gears made of POM. Depending on the configuration and application, the manufacture takes place in the following Process: For the fast delivery of a wear-resistant customer-specific gear wheel within a few days, the Cologne-based company resorts to 3D printing from the SLS material Iglidur I3. Mechanical processing from Iglidur semi-finished products is seen as the method of choice for large-volume gears, for example. And injection molding offers the greatest variety of Iglidur materials, especially for cost-effective series production of special dimensions.
Webinar on gear life calculation
31.08.2020/XNUMX/XNUMX | A gear wheel made of tribo plastics offers numerous advantages: In contrast to Metal Gear is light, quiet, self-lubricating and low-maintenance. But the question that arises here is what loads a plastic gear can withstand over what period of time? The answers to that are there Tom Krause, Head of Additive Manufacturing at Igus. In this online seminar he shows how the service life of a plastic gear is calculated and how it can be optimized during the design and construction.
Plastic gears are no longer just found in niches such as model making. Through the additive manufacturing There are now possibilities that were previously not feasible mechanically. “That applies, for example, to the optimization of the gearwheel geometry,” says Mr. Krause. "Since this is a comparatively new way of designing gears, we are now teaching in an online seminar how this potential can be used effectively."
The participants can then determine the service life of low-wear and lubrication-free tribo plastic gears in their moving applications. You can use the much more cumbersome one Load capacity calculation renounce. You will learn how to determine and optimize the tooth module and tooth width with the Igus tool.
3D printing gear 80% more wear-resistant
The online tools like the Iglidur designer and the Gear life calculator are free of charge and can be used without registration. The database of the gears comes directly from the Igus test laboratory. A series of tests showed that gears printed from Iglidur are around 80% more wear-resistant than conventional plastic gears. With more than 120.000 printed parts last year and eight SLS printers spread across Europe, Asia and America, additive manufacturing at Igus with eleven wear-resistant Iglidur materials is now one of the company's established production processes. And best of all: The 3D printed gears are ready for dispatch in just three days.
Configurator for ultra-robust plastic gears
17.10.2021/XNUMX/XNUMX | With the new configurator from igus, gears can now configured online in just 1 min and can be ordered directly in the web shop. The gears are printed in the 3D printing service from Iglidur I6 using the SLS process. The high-performance plastic specially developed for gears is characterized by its particularly high wear resistance and beats milled gears made of common materials such as POM and PBT in the test.
Constructing gears is due to the complex involute gearing almost impossible without aids. To make the work of the designers easier, the Motion Plastics specialist has now developed the gear configurator, a simple and practical tool with which users can individually configure gears, even with special dimensions. The data such as tooth module, number of teeth, width and inner diameter must be entered in just a few steps. A 3D model is then automatically displayed, which can be exported as a STEP file.
By uploading the file in 3D Print Service the configured gear made of the new, extremely durable SLS material Iglidur I6 can be ordered directly. With a click of the mouse, the user can order his gear from a quantity of 1 or request an offer. The individual gear is ready for dispatch within three days.
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Iglidur I6 was able to prove its particularly high wear resistance and longevity in the in-house 2750 m² test laboratory. In comparison with the materials commonly used up to now for SLS printing, Iglidur I6 was able to convince by far. In the test, a worm wheel with 5 Nm torque and 12 min-1 tested. The gear made of the laser sintering material PA12 already stopped after 521 cycles, because the coefficient of friction had risen so high. The glidur I6 gear showed only minor wear after 1 million cycles and was still fully functional. In the test, iglidur I6 was also able to assert itself clearly compared to milled gears: Cogs made of POM already showed total wear after 621.000 cycles, while milled gears made of PBT broke after 155.000 cycles.
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