Incorporating image processing for postanalysis of polymer-based gears

Abstract

The application of polymer gears has witnessed substantial growth recently, attributed to their distinct characteristics. These gears operate under intricate loading conditions, enduring complex mechanical and thermal stresses. Nonetheless, analyzing polymer gears presents complexity due to their comparatively lower strength and stiffness than metals, alongside their nonlinear viscoelastic traits. These features contribute to the intricacy of evaluating tooth wear and failure behavior across diverse loading scenarios. Capitalizing on advancements in image processing and high-resolution devices, the prospect of image-based postanalysis emerges as a promising route for appraising polymer gear performance. This methodology not only promises high precision but also circumvents the errors inherent in contact-based measurements due to its noncontact nature. The focus of this chapter is the image-driven assessment of specially designed wear-resistant polymer-based gears to quantify tooth wear and assess wear and failure patterns. To achieve this, polybutylene terephthalate nanocomposites reinforced with montmorillonite clay were employed as gear materials. Through the utilization of a tailor-made gear test rig and a digital camera, experimental tests were conducted and corresponding images were captured. Moreover, the digital image correlation technique was harnessed to gauge the surface strain on the gear teeth. © 2025 Elsevier B.V., All rights reserved.