Victrex polymer lightens Metaldyne's gears
A
Victrex product story
Edited by the Engineeringtalk editorial team
Mar 3, 2009
Metaldyne has chosen Victrex Peek polymer to replace metal in its balance-shaft module gears, resulting in a gear design that enhances performance and improves efficiency.
Aaron Clark, engineering manager for Metaldyne Powertrain Products, said: 'Compared with traditional iron and steel gears, the Victrex Peek polymer gear gives us about 70 per cent less inertia and weight.
'That is important because lower weight and inertia gives us about a 3-9 per cent reduction in power consumption, which results in improved fuel economy in the vehicle.
'Using Victrex Peek polymer for the gears also contributes to improved noise, vibration and harshness (NVH) performance.' Balance shaft modules are used to cancel the inherent shaking forces associated with in-line four-cylinder engines.
Clark added: 'Because the modules spin at twice engine speed, up to 15,000rpm, polymers are not normally used.
'The maximum operating temperature in four-cylinder engines is about 155C (311F) and most polymers can't survive in these conditions.
'We chose Victrex Peek polymer because it has the unique ability of not only being able to survive at 155C (311F), but also of maintaining all of its material properties including fatigue strength, chemical resistance, high temperature resistance and strength.
'The result is a gear that can perform at a very high level, not only in terms of durability and reliability but also in terms of improved NVH performance at elevated temperatures.' When compared with metal-gear production, gears made with Victrex Peek polymer require a substantially lower capital investment and have a shorter lead time.
Clark added: 'The lead time to manufacture the Victrex Peek polymer gears is roughly half that of metal gears.
'Because they are injection moulded, the Victrex Peek polymer gears require no post machining and this eliminates the need for grinding equipment.
'We can immediately assemble the gears into our balance-shaft modules and use them.
'This results in a significant cost saving.'.
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