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<p>The growing demand for lightweight and high performance mechanical components has accelerated the implementation of composite materials as alternatives to conventional metals. In this study, polyamide-66 spur gears reinforced with short carbon fibers (SCF) were investigated as lightweight alternatives to conventional metallic gears using an integrated numerical–experimental framework. Spur gears containing 0–60 wt% SCF were manufactured by injection molding and evaluated using FEA and fatigue testing on a custom gear test rig via Taguchi-based design of experiments. Static and dynamic FEA were employed to determine deformation, equivalent stress and fatigue life under operational torque and speed. Results show that increasing SCF content improves stiffness and fatigue resistance up to 40 wt%. The experimentally measured fatigue life increased from 2.63 × 10⁵ cycles for neat PA66 to 17.05 × 10<sup>5</sup> cycles for 40 wt% SCF/PA66, representing an improvement of approximately 6.5 times. Further increase in SCF content degrades the mechanical performance, which is attributed to increased brittleness. The 40 wt% SCF/PA66 composite showed minimum total deformation (0.1627&#xa0;mm) and maximum simulated fatigue life (18.7 × 10<sup>5</sup> cycles), which closely matches experimental results (17.05 × 10<sup>5</sup> cycles). Taguchi optimization found material composition as the principal parameter governing fatigue life, with 40 wt% SCF at 1135&#xa0;rpm producing the highest signal-to-noise ratio. The maximum operating temperature recorded at the gear tooth interface (82.6&#xa0;°C) remained noticeably below the composite melting temperature (260.9&#xa0;°C), which confirms thermal stability during operation. This study identifies 40 wt% SCF/PA66 as the optimal material composition and provides insight into the fatigue behaviour of fiber-reinforced polymer gears used in lightweight transmission systems.</p>

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Experimental and numerical investigation of short carbon fiber reinforced PA66 spur gears for fatigue performance optimization

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年5月20日

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  • Dilip S. Choudhari,
  • Rahul G. Deshmukh,
  • Yogesh G. Joshi,
  • G. D. Gosavi,
  • Sarang P. Joshi,
  • Mangesh D. Shende,
  • Arunkumar Bongale

摘要

The growing demand for lightweight and high performance mechanical components has accelerated the implementation of composite materials as alternatives to conventional metals. In this study, polyamide-66 spur gears reinforced with short carbon fibers (SCF) were investigated as lightweight alternatives to conventional metallic gears using an integrated numerical–experimental framework. Spur gears containing 0–60 wt% SCF were manufactured by injection molding and evaluated using FEA and fatigue testing on a custom gear test rig via Taguchi-based design of experiments. Static and dynamic FEA were employed to determine deformation, equivalent stress and fatigue life under operational torque and speed. Results show that increasing SCF content improves stiffness and fatigue resistance up to 40 wt%. The experimentally measured fatigue life increased from 2.63 × 10⁵ cycles for neat PA66 to 17.05 × 105 cycles for 40 wt% SCF/PA66, representing an improvement of approximately 6.5 times. Further increase in SCF content degrades the mechanical performance, which is attributed to increased brittleness. The 40 wt% SCF/PA66 composite showed minimum total deformation (0.1627 mm) and maximum simulated fatigue life (18.7 × 105 cycles), which closely matches experimental results (17.05 × 105 cycles). Taguchi optimization found material composition as the principal parameter governing fatigue life, with 40 wt% SCF at 1135 rpm producing the highest signal-to-noise ratio. The maximum operating temperature recorded at the gear tooth interface (82.6 °C) remained noticeably below the composite melting temperature (260.9 °C), which confirms thermal stability during operation. This study identifies 40 wt% SCF/PA66 as the optimal material composition and provides insight into the fatigue behaviour of fiber-reinforced polymer gears used in lightweight transmission systems.