A Surface Wear Prediction Framework and Performance Evaluation Strategy for Polymer Gears

With engineering architecture being shifted to meet the requirements of sustainable development, the need for optimized design solutions places precise engineering methods at the core of the contemporary industrial transition toward data-driven strategies. A timely conversion to lightweight components in drivetrain systems has led to the prominent use of high-strength polymer gears, establishing them as a critical point of interest in the field of power transmission. However, as the conversion to polymer gears relies on expensive and time-consuming laboratory testing, there is a standstill in evaluating the structural properties specific to polymer gear design. In addition, one of the major concerns in the development of polymer-based gear drives is linked with their operational performance and dynamic response under fault conditions influenced by surface wear. To address these difficulties, a framework for surface wear prediction is developed, enabling precise design optimization for specific drivetrain requirements. Computations of wear progression over multiple duty cycles are built upon the mathematical background of Archard’s wear theory, while internal changes in gear contact pressure distribution are constructed on Winkler’s surface model. The framework provides an innovative support for polymer gear systems, as it imports the three-dimensional (3D) scanning data of gear geometry, therefore enabling the analysis of actual flank surfaces with designated surface modifications and manufacturing errors. The framework’s effectiveness, confirmed by experimental validation, demonstrates a superior estimation of contact parameters and overall performance compared to traditional design methods, highlighting scalable solutions that contribute to ongoing industrial engineering objectives.