Process Design for Manufacturing Fiber-Reinforced Plastic Helical Gears Using a Rapid Heating and Cooling System

In this study, a lightweight fiber-reinforced plastic (FRP) helical gear was fabricated to investigate the potential application of FRP in automobile parts that require high loads and reduced noise. High-performance aramid FRP processed using the wet-laid method was used in the tooth region, and SCR420 steel was used in the inner hub region. A hot-forming system that combines rapid induction heating and water channel cooling methods was developed to reduce the cycle time. The cooling water flow conditions were analyzed to precisely control the mold temperature. Additionally, a rotating extraction system was developed to mitigate the extraction difficulty owing to the helix angle to the extraction direction. Using the innovative hot-forming system developed in this study, a helical gear without any process-induced defects was fabricated with a significantly reduced cycle time. The performance of the gear was successfully estimated using gear durability, torsional strength, and motion noise tests. The use of FRP materials offers significant potential to realize lightweight components; however, certain challenges related to their properties that may limit their application must be addressed on a case-by-case basis.

Automated summary

In this study, a lightweight FRP helical gear was fabricated for potential application in automobile parts requiring high loads and reduced noise. The gear was made using aramid FRP in the tooth region and SCR420 steel in the inner hub region. A hot-forming system combining induction heating and water cooling was developed to reduce cycle time. The gear's performance was successfully evaluated through durability, strength, and noise tests. The use of FRP materials offers significant potential for lightweight components, but challenges related to their properties must be addressed on a case-by-case basis.