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<p>This study investigates the thermal response and wear behavior of Nylon&#xa0;66 gears reinforced with embedded steel grid structures. Three variants were developed: Type I reinforced with glass fiber, Type II containing a single steel grid, and Type III incorporating multiple grid layers. All gears were produced through injection molding, and their mechanical, thermal, and surface properties were evaluated using standard laboratory procedures. Endurance tests were conducted at 1500&#xa0;rpm for 25 and 30&#xa0;kg loads in both dry and lubricated conditions to measure temperature rise, surface wear, and operational behavior. The results show that incorporating multiple steel grid layers improves heat transfer and reduces temperature buildup during continuous operation. Type III gears produced the highest thermal conductivity of 0.30&#xa0;W/m.K and showed a temperature drop of 7.5&#xa0;°C compared with the unreinforced gear. Atomic force microscopy indicated a smoother surface topology with a roughness value of 28.93&#xa0;nm, suggesting reduced friction at the gear interface. X-ray diffraction confirmed an amorphous polymer matrix in all gear types. Response surface methodology identified the 25&#xa0;kg lubricated condition as the most favorable for maintaining thermal stability. Overall, the multi-grid design improved heat management, structural reliability, and operational life, indicating its suitability for high-load and high-speed gear applications.</p>

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Structured Metal Grid Reinforcement for Thermal Fortification of Nylon-Based Composite Gears

  • 期刊论文

  • 发表日期：

    2026年1月12日

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  • Pradeep Kumar Seetharaman,
  • Gopinath Dhamodaran,
  • Arulkumar Elumalai,
  • Thennarasu Palani

摘要

This study investigates the thermal response and wear behavior of Nylon 66 gears reinforced with embedded steel grid structures. Three variants were developed: Type I reinforced with glass fiber, Type II containing a single steel grid, and Type III incorporating multiple grid layers. All gears were produced through injection molding, and their mechanical, thermal, and surface properties were evaluated using standard laboratory procedures. Endurance tests were conducted at 1500 rpm for 25 and 30 kg loads in both dry and lubricated conditions to measure temperature rise, surface wear, and operational behavior. The results show that incorporating multiple steel grid layers improves heat transfer and reduces temperature buildup during continuous operation. Type III gears produced the highest thermal conductivity of 0.30 W/m.K and showed a temperature drop of 7.5 °C compared with the unreinforced gear. Atomic force microscopy indicated a smoother surface topology with a roughness value of 28.93 nm, suggesting reduced friction at the gear interface. X-ray diffraction confirmed an amorphous polymer matrix in all gear types. Response surface methodology identified the 25 kg lubricated condition as the most favorable for maintaining thermal stability. Overall, the multi-grid design improved heat management, structural reliability, and operational life, indicating its suitability for high-load and high-speed gear applications.