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It’s Time to Scrap Metal Gears
VICTREX® PEEK: beyond the limits of Metal
VICTREX® PEEK – It’s Time to Scrap Metal Gears
LIgHTWEIgHT foR HEAVy uSE
Across all industry sectors, engineers designing gears are facing many simultaneous challenges. Solutions need to contribute to improved reliability, reduced noise, vibration, harshness (NVH) and greater efficiency, fit the trend for smaller components, and at the same time provide more design freedom and lower overall system costs compared to precision metal gears. VICTREX PEEK polymer is being used in an increasing number of applications where traditional metal components have been specified but no longer meet engineering requirements and it is well on the way to becoming the new reference in high performance gear applications.
Gears made of VICTREX® PEEK offer the following benefits compared to metal
s Up to 70% weight reduction
s Up to 80% reduced moment of inertia
s Up to 50% (3 dB) noise reduction
from Challenge to benefit with Victrex
Many companies still rely on metal gears only – but many others, for good reason, don’t! Industry leaders are now deploying new materials for their performance and cost benefits. Many of these innovations already rely on the advantages of our highly versatile VICTREX PEEK polymers.
Are you an OEM, designer or processor, who wants to move ahead of the competition? The outstanding mechanical and tribological properties of VICTREX PEEK meet the spectrum of complex mechanical demands for gear wheels perfectly. Being a true metal replacement option VICTREX PEEK performs successfully under extreme conditions and provides key benefits during all phases of the manufacturing process.
VICTREX® PEEK used in reliable and efficient gear solutions
s Higher comfort, less noise and vibration from a high damping capacity and extended design options
s Lower energy consumption due to significant weight reduction
s Improved responsiveness from a reduced moment of inertia
s Enhanced lifetime and extended service intervals due to very low friction and wear, corrosion resistance, and reduced need for lubrication
s Can be used in the most demanding environments due to its excellent resistance to chemicals, oil particle contamination and all known automotive fluids
s No swelling or loss of strength due to moisture absorption
Superior to metals: Manufacturing at lower costs
s Lower investment for high-volume production due to injection-molding manufacturing process compared to precision metal gears
s Faster production ramp-up and greater design freedom
s No secondary machining, hardening or finishing operations required
s Possibility of hybrid technology with metal, composites and other plastics
To support your decision to scrap metals and rely on VICTREX PEEK we can provide you with all the information you need. For example: data on noise and vibration or durability as well as further advice depending on your individual challenges.
Just ask our experts and trust in our application testing and development capabilities with two state-of-the-art test rigs for polymer gears.
Many of our partners already know VICTREX PEEK´s proven outstanding material properties for use in gear applications and its benefits compared to metal. We invite you to join their experience.
Proven Reliability
3000 rpm
3000 rpm
2000 rpm
2000 rpm
Input torque [nm]
Sou
nd
pre
ssu
re l
evel
[d
bA
]
88
86
84
82
80
78
76
740 1 2 3 4 5 6 7 8 9 10
VICTREX PEEK 1000 rpm
1000 rpm Iron
Sound level comparison between iron and VICTREX® PEEK gears at various loads and speeds
Thermal resistance for enhanced lifetime and reduced maintenance costs
Because of its high retention of mechanical properties at elevated temperatures and in hostile chemicals and moisture, VICTREX PEEK offers significant advantages over other gear materials and meets the industry’s requirements for longer lifetime in more demanding environments.
Significant rattle noise reduction: Perception of quality via the senses
Gears made of VICTREX PEEK run noticeably smoother. This results from the high damping capacity of the material and leads to reduced contact stress and higher contact ratios. For the human ear, up to 50% noise level reduction can be achieved by the lower noise, vibration, and harshness of VICTREX PEEK gears compared to metal gears.
The next generation
Victrex has developed a new PEEK for use in gear applications, improving the already excellent properties of VICTREX PEEK 450G, and offering enhanced lifetime in lubricated applications. The new VICTREX PEEK confers the technical and economic advantages of PEEK to even the most demanding gear applications, for example in automotive engines and transmissions, high speed printers and copiers and pumps in medical devices.
Thermal aging – 5.000 h @ 150°C in air
[%]
120
100
80
60
40
20
0Tensile strength Tensile modulus Tensile elongation Impact
Properties retention of VICTREX PEEK 450G
Thermal aging – Automotive lubricants
Material: 450CA30 Exposure time: 2,000 h
25
20
15
10
5
0
-5
-10-15
-20
-25
Ch
ang
es [
%]
Tensile strength
Elongation youngs-modulus
Charpy Charpy notched
Castrol MbX (200°C) Shell Spirax Mb90 (175°C)Mobil 1 (200°C)
Root stress versus no of cycles to failure (30°PA, 3000 rpm, lubricated)
Ro
ot
stre
ss (
MPa
)
120
100
80
60
40
20
010,000 100,000 1,000,000 10,000,000 100,000,000
no of cycles to failure
VICTREX PEEK new
VICTREX PEEK 450G
VICTREX® PEEK – It’s Time to Scrap Metal Gears
Success Stories of VICTREX® PEEK Gear Applications
Every industry has its own requirements. By talking and listening to our customers, we can contribute the right know-how and material solution according to the given needs. This level of support enables our partners, OEMs, and Tiers or their suppliers, to develop the right solution.
Balance shaft gears: Smoother running and higher system efficiency
To move ahead of its competitors, Metaldyne, an industry leader in balance shafts and balance shaft modules based in the US, relies on VICTREX PEEK 450G replacing metal gears in a balance shaft module to enhance performance and improve fuel efficiency.
The design engineers of Metaldyne, together with the US gear designer and producer Kleiss Gears, and in close collaboration with Victrex´s specialists, developed a novel gear design that delivers durability, reliability and improved efficiency.
s 3 dB improvement in NVH compared to cast iron gear set means 50% noise reduction
s 68% weight reduction resulting in 78% reduction of the moment of inertia compared to iron gear
s 9% less torque required to operate
Excellent properties – alternative to metals
s Retains high mechanical properties at temperatures of -40°C to 250°C
s Resistant to automotive fluids, especially long life engine and transmission oil
s Good dimensional stability – low CLTE
s Excellent dynamic fatigue resistance
s High durability in gear applications (up to 12,000 rpm)
Increased operating range for heating, ventilation and air conditioning
In HVAC actuator applications, VICTREX PEEK 450G has been used in spur gears. The system requirements were challenging for a compact actuator: temperature resistance up to 80°C; alternating movement +/- 90°; and torque level > 10 Nm. The required lifetime is 250,000 cycles.
The use of VICTREX® PEEK results in higher system efficiency
s More than 100% torque improvement
s Temperature range increased to 80°C
s Identical system dimensions / installation space
s Reduced number of parts
Applications also benefit from VICTREX PEEK´s high dynamic fatigue performance and dry running capabilities. The potential for cost reduction when compared to post treated sintered metal is also proving attractive for new system solutions.
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VICTREX PlC bElIEVES ThAT ThE InfORMATIOn COnTAInEd In ThIS bROChuRE IS An ACCuRATE dESCRIPTIOn Of ThE TyPICAl ChARACTERISTICS And/OR uSES Of ThE PROduCT OR PROduCTS, buT IT IS ThE CuSTOMER‘S RESPOnSIbIlITy TO ThOROuGhly TEST ThE PROduCT In EACh SPECIfIC APPlICATIOn TO dETERMInE ITS PERfORMAnCE, EffICACy And SAfETy fOR EACh End-uSE PROduCT, dEVICE OR OThER APPlICATIOn. SuGGESTIOnS Of uSES ShOuld nOT bE TAKEn AS InduCEMEnTS TO InfRInGE Any PARTICulAR PATEnT. ThE InfORMATIOn And dATA COnTAInEd hEREIn ARE bASEd On InfORMATIOn wE bElIEVE RElIAblE. MEnTIOn Of A PROduCT In ThIS dOCuMEnTATIOn IS nOT A GuARAnTEE Of AVAIlAbIlITy. VICTREX PlC RESERVES ThE RIGhT TO MOdIfy PROduCTS, SPECIfICATIOnS And/OR PACKAGInG AS PART Of A COnTInuOuS PROGRAM Of PROduCT dEVElOPMEnT. VICTREX® IS A REGISTEREd TRAdEMARK Of VICTREX MAnufACTuRInG lIMITEd. VICTREX PIPES™ IS A TRAdEMARK Of VICTREX MAnufACTuRInG lIMITEd. PEEK-ESd™, hT™, ST™ And wG™ ARE TRAdEMARKS Of VICTREX PlC. VICOTE® And APTIV® ARE REGISTEREd TRAdEMARKS Of VICTREX PlC.
VICTREX PlC MAKES nO wARRAnTIES, EXPRESS OR IMPlIEd, InCludInG,wIThOuT lIMITATIOn, A wARRAnTy Of fITnESS fOR A PARTICulAR PuRPOSE OR Of InTEllECTuAl PROPERTy nOn-InfRInGEMEnT, InCludInG, buT nOT lIMITEd TO PATEnT nOn-InfRInGEMEnT, whICh ARE EXPRESSly dISClAIMEd, whEThER EXPRESS OR IMPlIEd, In fACT OR by lAw. fuRThER, VICTREX PlC MAKES nO wARRAnTy TO yOuR CuSTOMERS OR AGEnTS, And hAS nOT AuThORIZEd AnyOnE TO MAKE Any REPRESEnTATIOn OR wARRAnTy OThER ThAn AS PROVIdEd AbOVE. VICTREX PlC ShAll In nO EVEnT bE lIAblE fOR Any GEnERAl, IndIRECT, SPECIAl, COnSEQuEnTIAl, PunITIVE, InCIdEnTAl OR SIMIlAR dAMAGES, InCludInG wIThOuT lIMITATIOn, dAMAGES fOR hARM TO buSInESS, lOST PROfITS OR lOST SAVInGS, EVEn If VICTREX hAS bEEn AdVISEd Of ThE POSSIbIlITy Of SuCh dAMAGES, REGARdlESS Of ThE fORM Of ACTIOn.
World HeadquartersVictrex plchillhouse InternationalThornton Cleveleyslancashire fy5 4Qdunited KingdomTel: + (44) 1253 897700fax: + (44) 1253 897701Email: [email protected]
AmericasVictrex uSA Inc300 Conshohocken State RoadSuite 120 west Conshohocken, PA 19428uSATel: + (1) 800-VICTREXTel: + (1) 484-342-6001fax: + (1) 484-342-6002Email: [email protected]
EuropeVictrex Europa Gmbhlanggasse 1665719 hofheim/Ts.GermanyTel: + (49) 6192 96490fax: + (49) 6192 964948Email: [email protected]
Asia PacificVictrex Japan Inc.Mita Kokusai building Annex4-28, Mita 1-chomeMinato-kuTokyo 108-0073JapanTel: +81 (0)3 5427 4650fax: +81 (0)3 5427 4651Email: [email protected]
Asia PacificVictrex high Performance Materials (Shanghai) Co ltdPart b building G no. 1688 Zhuanxing RoadXinzhuang Industry Park Shanghai 201108ChinaTel: + (86) 21-6113 6900fax: + (86) 21-6113 6901Email: [email protected]
Victrex Polymer Solutions, a division of Victrex plc, is the world’s leading manufacturer of Polyaryletherketones, high performance polymers, which are sold under the brand names VICTREX® PEEK polymer, VICOTE® Coatings, APTIV® films and VICTREX Pipes™. with production facilities in the uK backed by sales and distribution centres serving more than 30 countries worldwide, our global market development, sales, and technical support services work hand-in-hand with OEMs, designers and processors offering assistance in the areas of processing, design and application development to help them achieve new levels of cost savings, quality, and performance.
www.victrex.com
