Two-Step PM Procedure for Fabrication of Super-Engineering Plastic Gears

Abstract

The two-step PM (powder metallurgy)-route procedure was proposed to fabricate a super-engineering plastic gear directly from powder feedstock. Its lightweight, fully dense integrity and high-stiffness has been found to be suitable for reducers in robotics and electric vehicles, as they work even in severe environmental conditions. In this study, the green compaction and sinter-forging processes were used to consolidate the polyimide powder feedstock and to sinter forge the solid preform into the final products. To demonstrate the high density of preforms and sinter-forged gears, a hardness measurement and X-ray computer tomography were employed. The gear-grade balancing was also evaluated to describe the effect of fine sinter-forging conditions on the dimensional quality of polyimide gears. High gear grade with JIS-2 class proved that the polyimide was useful as a matrix of lightweight and high-strength gears.