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Journal of Polymer & Composites Review Article Special issue

A Systematic Review of Advanced Composite Materials for High-Performance Spur Gear Applications

  1. Rishikesh Hanmant Tike Department of Mechanical Engineering, Progressive Education Society's Modern College of Engineering, Shivajinagar, Pune
  2. Nitish Kumar Gautam Dept. of Mechanical Engineering, Shri Jagdishprasad Jhabarmal Tibrewala University, Vidyanagri, Jhunjhunu
  3. Tarun Kumar Yadav Department of Mechanical Engineering, Babulal Tarabai Institute of Research & Technology, Sironja
  4. Swapnil Deokar Department of Mechanical Engineering, Smt. Kashibai Navale College of Engineering Vadgaon, Pune
  5. Ritesh Fegade Department of Mechanical Engineering, Parvatibai Genba Moze College of Engineering, Savitribai Phule Pune University, Wagholi, Pune
  6. Rupendra Nehete Department of Mechanical Engineering, SIES Graduate School of Technology, Nerul, Navi Mumbai
  7. Vithoba Tale Department of Mechanical Engineering, Rajarshi Shahu College of Engineering, Tathawade, Pune
  8. Ramakant Chaudhari Department of Mechanical Engineering, Padmashri Dr. V. B. Kolte College of Engineering, Malkapur
  9. Gitanjali Kale Department of First year Engineering, Dr. DY Patil Institute of Technology (DIT), Pimpri, Pune

Abstract

This is a review which provides specific and detailed information regarding the fiber-reinforced polymer (FRP) composite to replace traditional steel in high-performance spur gears with emphasis on mechanical performance, computational modeling, and experimental validation. Methods: The current literature was thoroughly investigated that includes material properties, material simulation (e.g., finite element analysis, FEA), and experimental gear testing procedures (e.g., DIN 51354, ASTM G99). Certain case studies in the aerospace and automotive sectors were analyzed. Key Findings: Weight Reduction: Composite gears (e.g., CFRP, GF30-PEEK) are 30–50 percent lighter than steel gears, and CFRP has a specific strength of 3.46 GPa·cm³/g compared to 0.47 GPa·cm³/g of AISI 4340 steel—a 7.4 times improvement. Structural Performance: CFRP gears under a 50 Nm torque load, according to FEA simulations, have up to 40% less deformation (0.012 mm vs. 0.020 mm in steel) and 29% less stress concentration factors. Durability and Tribology: GF30-PEEK has a high wear resistance and lubricated wear rates as small as 1.8 × 10–6 mm³/Nm. CFRP gears exhibit high impact resistance and can resist 85 J/m Charpy impact, a factor 3 times higher than 25 J/m of nylon six six. Dynamic Behavior: The damping behavior of polymer composites decreases vibration by 15–20 dB and noise by 8 dB with natural frequencies that are 15% higher (CFRP: 2.8 kHz Steel: 2.4 kHz). Inference: FRP composite spur gears are a revolutionary solution to the power transmission systems and have considerable benefits in terms of weight reduction, life cycle, and sound abatement. The next steps to be undertaken in the field of work are multiscale wear modeling, AI-based optimization, and sustainable lifecycle management to allow wider application in the areas of electric mobility and aerospace, as well as advanced robotics.

Keywords

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