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<p>This study proposes a&#xa0;method for evaluating the deformation occurring during the molding process of injection-molded plastic gears. Injection-molded plastic gears experience differences in temperature and pressure depending on the position of the plastic inflow within the mold, leading to defects such as warpage in the out-of-plane direction of the gear flanks, which consequently degrade gear accuracy. However, conventional gear accuracy evaluation methods do not consider these injection molding-specific deformations, making it difficult to assess the overall gear geometry comprehensively.</p><p>To address this issue, this study proposes an analysis method that evaluates the cross-sectional shape formed by the deviation curves of the left and right tooth helices, thereby assessing the accuracy degradation caused by injection molding defects. The proposed method was applied to actual injection-molded gears, revealing that the entire gear flank on the gate side exhibited shrinkage deformation. Additionally, it was observed that the twist direction of the teeth changed across the weld line. These findings demonstrate the effectiveness of the proposed method in providing a&#xa0;comprehensive evaluation of gear accuracy.</p>

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Shape evaluation of all transverse sections bounded by the left and right tooth helix deviations of injection-Molded plastic gears

  • 期刊论文

  • 发表日期：

    2025年9月5日

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  • Yuichiro Seo,
  • Daisuke Iba,
  • Jing Chong Low,
  • Shunta Takahashi,
  • Shu Takata,
  • Naoki Yamashita,
  • Junichi Hongu

摘要

This study proposes a method for evaluating the deformation occurring during the molding process of injection-molded plastic gears. Injection-molded plastic gears experience differences in temperature and pressure depending on the position of the plastic inflow within the mold, leading to defects such as warpage in the out-of-plane direction of the gear flanks, which consequently degrade gear accuracy. However, conventional gear accuracy evaluation methods do not consider these injection molding-specific deformations, making it difficult to assess the overall gear geometry comprehensively.

To address this issue, this study proposes an analysis method that evaluates the cross-sectional shape formed by the deviation curves of the left and right tooth helices, thereby assessing the accuracy degradation caused by injection molding defects. The proposed method was applied to actual injection-molded gears, revealing that the entire gear flank on the gate side exhibited shrinkage deformation. Additionally, it was observed that the twist direction of the teeth changed across the weld line. These findings demonstrate the effectiveness of the proposed method in providing a comprehensive evaluation of gear accuracy.