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Materials used in plastic gears are, in general, engineering plastics such as polyacetal (POM) and MC Nylon which is essentially polyamid resin. In addition, U-PE and PEEK can be used.
When there is a large temperature fluctuation in the application environment, when the diameter is large or when there is load on its keyway, metal hub made of S45C or stainless steel may sometimes be used. In these cases, the teeth portion and the hub portion are attached together with screws. If it is not possible to screw together, two parts are fused together and made into fused gears. Enqi’s fused gears are designed in such a way that the holding strength of the fused surface is stronger than the tooth strength.
The positive characteristics of plastic gears include being lightweight, non-rusting, quiet, injection molding enabling low cost and large production, and able to operate without lubrication by mating with metal gears. On the other hand, low strength, tendency to hold heat, large dimensional change including backlash compared to metal, etc. are some of the points requiring caution. The degree of dimensional changes that occur with plastic gears depend on the ability to resist temperature change, moisture absorption rate and resistance to chemicals.
As far as the applications of plastic gears, they are used in varying industries such as food production machines, consumer electronics, chemical, toy, and medical equipment industries.
The materials used for producing plastic gears are typically one of two types.
One type of engineering plastic is called POM. It is also known by the tradename Duracon or its generic name, acetal copolymer. The other is MC nylon. It’s a polyamide resin and is called nylon 6 as well.
Because both are smooth materials, they don’t typically require lubrication with grease or oil. They are softer than metals, thus effective for noise reduction with a high vibration absorptance. The common characteristics of both materials are that they are lighter than metals and resistant to corrosion from salt.
When comparing a POM gear and MC nylon gear, the biggest difference one may point out is the difference in the forming method. POM is made by pouring melted resin into a metal mold while applying pressure, which is called injection molding. Due to its high formability, the gear shape can be obtained by simply having a mold in the gear shape. On the other hand, MC nylon gears are generated by cutting. Similar to casting metal gears, melted resin is poured into a mold without applying pressure to create a rough shape such as cylinder, pillar, or disk and then the gear teeth are formed by cutting.
With those differences, POM is suitable for producing small gears in larger quantities and MC nylon is suitable for producing large gears or small lot gears.
Another big difference between POM and MC nylon can be found in absorbency. Though it depends on the environment, MC nylon absorbs water 10 times more than POM does. Absorbing water lowers dimensional accuracy and consequently produces noise or lowers the transmission efficiency of torque. Additionally, a deterioration of resin occurs due to hydrolysis, therefore POM is more suitable as a material of gears that are going to be used in high humidity or where water touches.
Furthermore, there’s a difference in mechanical properties as well. MC nylon is better in terms of mechanical properties because of the tensile strength and bending strength. For instance, the bending strength of MC nylon is 1.2 times stronger than POM. As a plastic gear, MC nylon is more suitable when a large force is applied.
One should choose a suitable material after considering the number of gears that are needed, the force on the gear, and also surrounding environment such as humidity and chemicals.
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