Braided carbon fiber composite gears demonstrate outstanding mechanical properties, including low density, high specific stiffness, high specific strength, and exceptional impact resistance, effectively addressing the delamination issues commonly associated with laminated composite gears. As braiding technology continues to evolve and manufacturing processes become increasingly automated, braided carbon fiber composite gears have emerged as a promising alternative, attracting substantial interest from both academia and industry. However, braided carbon fiber composite gears exhibit substantial differences from conventional metal gears in terms of material composition, fabrication processes, and manufacturing methodologies. At present, no standardized frameworks exist for the calculation or experimental evaluation of their strength properties. This research aims to bridge the gap in strength performance data for braided carbon fiber composite gears through an experimental study on the bending strength of a 2.5 dimension braided carbon fiber composite gear. The experiments were conducted using an electro-hydraulic servo static-dynamic testing system, applying a single-tooth loading methodology. The gear was subjected to both cyclic stepwise loading and static loading tests to evaluate its mechanical response under varying loading conditions. Strain measurements were performed to determine the bending stress at the tooth root corresponding to different load levels. The experimental results revealed that, under cyclic stepwise loading, the gear initially exhibited surface crushing, without any evidence of bending fatigue failure at the tooth root. The static loading tests recorded a bending strength limit stress of 1705.38 MPa, providing essential data to support the engineering application and future development of braided carbon fiber composite gears.

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Test Study of Bending Strength of 2.5 Dimension Braided Carbon Fiber Composite Gear

  • La-yue Zhao,
  • Ji-xuan Bian,
  • Liu-Yang Guo,
  • Ming-xing Du

摘要

Braided carbon fiber composite gears demonstrate outstanding mechanical properties, including low density, high specific stiffness, high specific strength, and exceptional impact resistance, effectively addressing the delamination issues commonly associated with laminated composite gears. As braiding technology continues to evolve and manufacturing processes become increasingly automated, braided carbon fiber composite gears have emerged as a promising alternative, attracting substantial interest from both academia and industry. However, braided carbon fiber composite gears exhibit substantial differences from conventional metal gears in terms of material composition, fabrication processes, and manufacturing methodologies. At present, no standardized frameworks exist for the calculation or experimental evaluation of their strength properties. This research aims to bridge the gap in strength performance data for braided carbon fiber composite gears through an experimental study on the bending strength of a 2.5 dimension braided carbon fiber composite gear. The experiments were conducted using an electro-hydraulic servo static-dynamic testing system, applying a single-tooth loading methodology. The gear was subjected to both cyclic stepwise loading and static loading tests to evaluate its mechanical response under varying loading conditions. Strain measurements were performed to determine the bending stress at the tooth root corresponding to different load levels. The experimental results revealed that, under cyclic stepwise loading, the gear initially exhibited surface crushing, without any evidence of bending fatigue failure at the tooth root. The static loading tests recorded a bending strength limit stress of 1705.38 MPa, providing essential data to support the engineering application and future development of braided carbon fiber composite gears.