Naložbo sofinancirata Republika Slovenija in Evropska unija iz Evropskega sklada za regionalni razvoj.
Development of new technologies for managing Gear geometry on components produced out of polymer materials
Project duration (1.10.2016- 9.9.2018)
Expected project costs: 594.320,00€
Cofinanced amount: 208.012,00 €
Polymer (plastic) mechanical elements, which are an integral geometric part of gear toothing, have been used in different industries (car, appliances, office equipment, control technology, ...) for over 20 years.
In the last 10 years, when polymers started to replace metals once polymer materials reached metal materials in mechanical properties, the competitive priority became the ability to produce toothing geometry according to required quality levels.
Specifically, gears made from polymer materials have many advantages over gears made from metal materials. These advantages are: better lubricating properties; vibration damping, what leads to a longer life time of the final product which the polymer Gear components are part of; less noise; better chemical resistance; lower product weight and cheaper manufacture.
The current position of the polymer gears injection tool development market states that grade 10 is a standard (even in our tool shop), grade 9 is possible to manufacture only in few tool shops in Europe and grade 8 tools are possible to manufacture only in special (lab) conditions thus they are not suitable for mass production.
With this project we will make a breakthrough in the market of polymer gears and move the frontier for elements mass production to quality 7.
Polycom currently manufactures plastic gears at tolerance grade 10.
The expected final result of the RRI project is therefore to develop a process for the manufacture of polymer injection mechanical elements which also consist of toothing at tolerance grade 7 or higher.
We have to connect knowledge from many different areas (interdisciplinary approach) in the project to be able to achieve the final result, which means we will have to take this into account when the project group is formed.
In the area of mechanical engineering, we will develop a process of tool parts with a tolerance area of ±5μm.
This implies innovative manufacturing with a minimum of required operations, as each step in the process can potentially lead to errors.
We will develop strictly dedicated software for the programming of the production machinery for the treatment of metal parts, which will be based on elementary mathematics.
In the field of metrology, we will develop innovative preparations and procedures, with which we will eliminate potential errors of the measuring equipment and also receive a clear picture on toothing quality in each phase.
This will help us to accelerate the process of new tool development and reduce the number of correction cycles.
In the field of injection, we will develop a process which will help us to control more injection parameters than is standard in our practise and in doing so provide more constant conditions for manufacturing.
In terms of economic innovation, we will develop new techniques for service promotion which will lead to faster, more innovative and more effective transfers of our products to the market.
For better marketing support, we will develop new methods for forming products and service prices.