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SAE TECHNICAL
PAPER SERIES
1999-01-0851
The Effect of Internal Lubricants on the Accuracy
of Injection Molded Thermoplastic Gears
Edward H. Williams III
LNP Engineering Plastics
Roderick E. Kleiss
Kleiss Gears
Reprinted From: Plastic Components, Processes, and Technology
(SP-1410)
International Congress and Exposition
Detroit, Michigan
March 1-4, 1999
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1
1999-01-0851
The Effect of Internal Lubricants on the Accuracy of Injection
Molded Thermoplastic Gears
Edward H. Williams III
LNP Engineering Plastics
Roderick E. Kleiss
Kleiss Gears
Copyright 1999 Society of Automotive Engineers, Inc.
ABSTRACT
This paper will examine the effect that PTFE, silicone and
other internal lubricants have on the mold shrink rate of
thermoplastic gear materials and the resulting effect on
the accuracy of the molded gear. "Standard" thermoplas-
tic mold shrinkage data is generated on relatively large
test samples which do not represent the flow, orientation
and heat transfer seen in a typical molded gear. Addi-
tionally, different parts of the gear can be expected to
shrink at different rates, leading to potential errors if a sin-
gle "generic" mold shrink rate is used to design and
machine the gear mold cavity. Using a single cavity gear
mold, the shrink rate of different internally lubricated gear
materials is measured and compared to the unlubricated
base resin. The shrink rate of individual parts of the gear
are compared, as well as the resultant total composite
variation. A discussion on the techniques used to mea-
sure the gears, as well as the expected consequences of
the resultant shrinkage on the gear train, will be included.
This data can be used to increase the accuracy of
molded thermoplastic gears.
INTRODUCTION
The use of engineering thermoplastic resins like nylon 6/
6 and acetal to reduce cost, noise and weight in automo-
tive actuators has become common. Gear designers are
also considering thermoplastic compounds that have
had their performance enhanced by the addition of inter-
nal reinforcements and lubricants. While these com-
pounds are often selected as the primary candidate for
an application, it is also common for the compound to be
used to solve a problem in an existing application origi-
nally specified in an unlubricated thermoplastic material.
In these situations, the lubricated compound is usually
molded in the existing tooling without modification. It has
been customary to consider the effect of internal lubri-
cants on mold shrinkage as negligible in most gearing
applications because the parts are usually small, and
many applications have successfully used internally lubri-
cated materials in replacement of non-lubricated materi-
als. But as gear designers begin considering lubricated
materials in the initial design stage, the effect of mold
shrinkage on gear elements becomes increasingly impor-
tant.
THERMOPLASTIC MOLD SHRINKAGE
Typically, the mold shrinkage values given for a material
have been determined by measuring the shrinkage of a
5" x 1/2" x 1/8" rectangular bar measured in accordance
to ASTM D-955 test methods. These values are usually
given corresponding to the dimension parallel (flow) and
perpendicular (transverse) to the direction of melt flow in
the part. They are normally expressed as "inch/inch" or
sometimes as a percentage. These mold shrinkage val-
ues can be useful in comparing the relative shrink rate of
one material to another, but they should not be treated as
absolutes. Mold shrinkage can and will vary with part
thickness, mold layout, processing variations, and mold
temperature.
Of greater value is mold shrinkage data collected on an
actual part, whether it be a simple prototype mold or a
similar application. It was this approach that was used to
study the effect internal lubricants has on the mold
shrinkage of different parts of a gear, and how that
shrinkage would affect the overall accuracy of the gear.
MATERIALS AND LUBRICANTS
To explore the effect of internal lubricants on the accu-
racy of injection molded gears, it was desirable to look at
both crystalline and amorphous resins. The crystalline
resins nylon 6/6 (PA 6/6) and acetal (POM), and the
amorphous resin polycarbonate (PC) were chosen for
this study. Crystalline materials will generally have much
higher shrinkage rates than amorphous materials. The
molecular structure of crystalline materials allows the
polymer chains to align in an ordered structure as the
molecules cool. This alignment allows a greater amount
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of shrinkage, and imparts some directionality to the
shrinkage (anisotropic shrinkage). Conversely, an amor-
phous resins molecular structure does not allow the
chains to align and the orientation remains random. This
random orientation results in less overall shrinkage with
little directionality (isotropic shrinkage).
The internal lubricants chosen for this study were PTFE,
silicone, combinations of PTFE and silicone, and four
proprietary, non-PTFE/silicone alloys. PTFE and silicone
are widely used in thermoplastic compounds to reduce
wear and friction in all types of thermoplastics. Recent
work in low cost lubricant systems have resulted in sev-
eral different alloy systems in acetal, nylon and polycar-
bonate compounds. Table 1 lists the specific materials
used in this study.
MOLD AND GEAR DESIGN
A standard 3-plate mold design was chosen with 3 sym-
metrical pin gates for injecting the plastic. A three-plate
mold has the advantage of separating the runner from
the part in the mold press and it allows an axial injection
path for the plastic, which results in a more concentric
gear. The gear cavity itself was designed as a simple
laminate disk that was doweled into the mold base. This
simple disk has no other features than the gear cavity
shape. By designing the cavity in this fashion, the gear
shape could be modified quite easily for additional stud-
ies of other gear forms or to mold exact parts from differ-
ent shrinkage materials.
The gear itself was designed as a 26 tooth, 24 Diametral
Pitch, 20 degree AGMA class PT-1 tooth form. The size
and shape of the gear were chosen to represent a rea-
sonable approximate size to many of the plastic gears
that are on the market today. The PT-1 tooth form is very
similar to the AGMA fine pitch gear with the exception of
its root geometry, which has a larger fillet radius for
added strength. Since many materials would be molded
in the same cavity with many different shrink rates, the
gear cavity was sized for the highest shrinkage material;
other materials processed in the same cavity would all be
larger than the initial target gear.
INSPECTION
Inspection of plastic gears must necessarily begin with
the cavity, since gear shrinkage can only be understood
by knowing the exact geometry of the form from which it
shrinks. For this study the gear cavity was constructed
with the following dimensions and estimations of shrink-
age for unlubricated acetal homopolymer:
Mold Temp. = 200F
The target dimensions for the molded gear after shrink-
age and the actual measured dimension of first part sam-
ples from the mold are tabulated below in Table 3.
Since this cavity was intended for general purpose mold-
ing of varied materials, further refinement of molded gear
dimensions was not warranted at this time.
Table 1. Materials Tested
Material Description
K-1000 D Unlubricated acetal homopolymer
KL-4040 D 20% PTFE, acetal homopolymer
K-1000 Unlubricated acetal copolymer
KL-4410 2% silicone, acetal copolymer
KL-4040 20% PTFE, acetal copolymer
KL-4540 2% silicone, 18% PTFE, acetal copolymer
Lubriloy K proprietary lubricated acetal alloy
Lubriloy KL proprietary lubricated acetal alloy
R-1000 unlubricated nylon 6/6
RL-4030 15% PTFE , nylon 6/6
RF-1006 30% glass fiber, nylon 6/6
RFL-4036 15% PTFE, 30% glass fiber, nylon 6/6
RA-1002 10% aramid fiber, nylon 6/6
RAL-4022 10% aramid fiber, 10% PTFE, nylon 6/6
Lubriloy RW proprietary lubricated nylon 6/6 alloy
D-1000 unlubricated polycarbonate
DL-4030 15% PTFE, polycarbonate
DF-1006 30% glass fiber, polycarbonate
DFL-4036 15% PTFE, 30% glass fiber, polycarbonate
Lubriloy D-EP proprietary lubricated, high flow polycarbonate
alloy
Table 2.
Cut
Dimension
(in)
Shrinkage
Estimate
(in/in)
Actual
Shrinkage
(in/in)
Number of teeth 26
Diametral Pitch 23.14 0.037 0.036
Pressure Angle 20
Tooth Thickness 0.0650 -0.0069 0.005
Outside Diameter 1.2057 0.035 0.0340
Root Diameter 1.0076 0.038 0.0369
Table 3.
Target Actual
Diametral Pitch 24 23.98
Pressure Angle 20 20
Tooth Thickness (in) .06545 .0647
Outside Diameter (in) 1.1667 1.1647
Root Diameter (in) 0.972 0.9704
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Profile inspection of both gears and cavities was per-
formed on an analog scanning coordinate measurement
machine. This machine has an NIST traceable volumetric
accuracy of 40 inches with a resolution of 4 inches.
Complete profile scans were taken of all teeth for both
the cavity and the gear. This is necessary for wire EDMd
cavities since a machining anomaly can occur anywhere
in this non-generative gear cutting process. We devel-
oped our own software to analyze the data for shrinkage,
eccentricity, tooth form, and tooth thickness.
In addition to profile measurement, we roll-tested the
molded unlubricated acetal homopolymer gears with a
custom wire EDM master gear. This gear was designed
with a low number of teeth in order to accentuate tooth-
to-tooth variations due to shrinkage variations.
Roll testing is incapable of accurately determining the
geometric accuracy of molded plastic gears, but it is
invaluable as a process capability check, and as a deter-
minant of eccentricity and lobing. Since we molded many
materials with many different shrinkages in a single cav-
ity, we were unable to use this 24DP master gear for most
of our inspections. In point of fact we rolled the plastic
gears against themselves as a redundant check on mea-
surements gained through profile inspection.
The examination of roll testing results with gear profile
analysis also points out another fallacy in trying to define
molded plastic gears in terms of their cut metal gear
counterparts. Test pitch radius, the radius to the gears
theoretical pitch circle, which is a dominant descriptive
feature in cut metal gears, has much less meaning for
molded gears since the pitch radius varies as a function
of shrinkage. It is much simpler and more meaningful to
define the gear with reference to its basic definable geo-
metric features.
ANALYSIS
The measured gear dimensions were compared to the
measured dimensions of the mold cavity to determine the
amount of shrinkage for each material. The mold tem-
perature for the materials that were to be compared was
held constant, so shrink rates would not influence the
resultant measurements. Table 4 lists the mold tempera-
ture and measured dimensions for each of the materi-
als. Table 5 lists the resultant mold shrinkage and Table
6 lists the difference in the measured dimensions of the
lubricated material to its unlubricated base resin.
It is clear from the data collected that adding and internal
lubricant to a material, whether the unreinforced base
resin or a reinforced compound, will change the mold
shrink rate of the compound. The shrink rate was also
different for the five "components" measured, with the
greatest differences being between the "bulk" features
(outside diameter, root diameter, base circle diameter)
and "fine" features (tooth thickness, tooth height). The
overall mold shrinkage rate measured in the gears was
greater than the mold shrinkage rate measured using
ASTM type procedures, which reinforces the caution
against using standard shrinkage values to cut gear cavi-
ties. The general effect of adding lubricants can be sum-
marized as follows:
PTFE Adding 20% PTFE to either copolymer or
homopolymer acetal reduced the shrinkage rate for all
the individual gear components except tooth height,
which increased.
Adding 15% PTFE to unfilled nylon 6/6 increased the
shrink rate for all components, most likely due to a slight
nucleating effect from the PTFE particles. Adding 15%
PTFE to a 30% glass fiber reinforced nylon 6/6 had the
same effect, except the shrink rate in the tooth height
was decreased. Adding 10% PTFE to a 10% aramid fiber
reinforced nylon 6/6 gave similar results as adding PTFE
to acetal, the overall effect being to reduce the shrink rate
for all components except tooth height, which increased.
Adding 15% PTFE to unfilled polycarbonate reduced the
shrink rate in the tooth height and tooth thickness, but
increased the rate in the other components. Adding 15%
PTFE to 30% glass fiber reinforced polycarbonate
reduced the shrink rate in all components except the
base circle diameter.
SILICONE Silicone was only evaluated in the acetal
copolymer. Adding 2% silicone to an acetal copolymer
slightly reduced the shrink rate of all tooth components.
Silicone had the smallest and most uniform effect on gear
shrinkage of all the lubricants evaluated in acetal. A
combination of 2% silicone and 18% PTFE in acetal
copolymer reacted similarly to just 20% PTFE.
ALLOYS As expected, the low cost, non-PTFE/silicone
alloy lubrication systems worked differently in each base
resin, because a different system is used in each one.
The net effect in acetal was the same as PTFE, reducing
the shrinkage rate for all the individual gear components
except tooth height, but to a lesser extent. This should
be expected, since the total amount of lubricant in the
alloy products is less than the PTFE lubricated samples.
The results for the nylon 6/6 based alloy system was an
increase in shrink rate over unfilled nylon 6/6, except for
the shrinkage in the tooth height, which increased.
The polycarbonate based alloy showed a reduction in
shrink rate for all gear components except root diameter.
EFFECT ON GEAR MESH Measuring the different
shrink rates is useful for understanding how a gear cavity
might be cut to accommodate different material combina-
tions, but how does it effect the engineer who wants to
substitute a lubricated material for an already designed
unlubricated gear in production. As stated before, these
situations are common applications for lubricated ther-
moplastic compounds and have been successful. The
effect of the change in shrinkage is primarily to change
the amount of backlash in the system.
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For example, our test mold was designed to mold acetal
homopolymer at 180F to give a 24 diametral pitch gear
with 26 teeth using the AGMA PT-1 tooth form. Meshed
against itself at "standard" center distance of 1.0830" it
should have 0.0028" of backlash. Our actual molded
gear was 23.944 diametral pitch, with an outside diame-
ter of 1.1666" and a tooth thickness of 0.0637". Mounting
this gear at the previous "standard" center distance
results in only 0.0016" of backlash. A 20% PTFE filled
acetal homopolymer, molded in the same mold at the
same temperature resulted in a gear with a 23.834
diametral pitch, 1.1719" outside diameter and a tooth
thickness of 0.0064". This gear, mounted on the original
1.0830" standard center distance would now have -
0.0024" of backlash and could not be mounted, let alone
operate.
The good news is that gears are seldom designed to
operate at "standard" center distances. The center dis-
tance is usually increased over standard to compensate
for variations in the gear housing, runout in the gears,
temperature and humidity variation, and other tolerance
concerns. It is also possible to change the mold shrink-
age rate of a material by varying process conditions like
mold temperature and cooling time. Taking advantage of
these factors often allows material substitutions to work
in the existing gear train using existing tooling. The
caveat to gear designers is that the gears are not the
same as the original gears, and more than likely they will
be running at reduced center distances, with less back-
lash, and greater specific sliding ratios.
EFFECT ON ACCURACY To evaluate the accuracy of
the molded gears, it would be common to roll the gears
against a 24 diametral pitch master gear and compare
the total composite variation and tooth-tooth error in the
gears. Using this technique can be misleading, since the
molded gears are not actually 24 diametral pitch and will
not properly mesh with the master gear. It is, however,
the method most commonly used to evaluate the molded
parts.
When the unfilled acetal homopolymer gear was rolled
against a 24 diametral pitch master (48 teeth), it had a
total composite error of 0.0011" and a tooth-to-tooth error
of 0.0006", and could be classified as an AGMA Q10.
The 20% PTFE lubricated acetal homopolymer gear
molded in the same cavity at the same process condi-
tions gave a 0.0014" total composite error and 0.0006"
tooth-to-tooth error, and could be classified as an AGMA
Q9.
Despite being rather accurate molded plastic gears, both
gears maximum test radius exceeded the calculated
"standard" test radius expected from 24 diametral pitch,
26 tooth gears with standard tooth profile. The unfilled
acetal homopolymer was 0.0018" larger, and the 20%
PTFE lubricated acetal homopolymer was 0.0054" larger.
The reason for the larger than expected test radius is two
fold. Not only are the gears larger in diameter, but the
diametral pitch of the molded gear and the master gear
no longer match. The mold shrinkage "errors" have
resulted in the diametral pitch of the gears to be smaller
than the 24 diametral pitch master, so the teeth of the
molded gears will not drop fully into the spaces between
the master gear teeth. This mismatch, plus the increased
diameters of the molded gears, combine to increase the
test radius of the gear when mated with a "standard"
master gear.
CONCLUSION
The overall effect of adding a lubricant to a gear
material is to reduce the shrinkage, resulting in a
larger gear.
If the molded part is thicker than an ASTM test sam-
ple (1/8"), then the shrink rate will be larger than that
reported for a standard ASTM shrink specimen.
The rate of shrinkage for any one material is different
for different components of the gear.
The main effect of lubricants on accuracy is to
increase the test radius of the gear and to enhance
the lobing effect created by the weld/meld lines.
REFERENCES
1. "The Effect of Filler, Wall Thickness and Geometry
on Shrinkage and Warpage of Engineering Thermo-
plastics" Josh McIlvaine, LNP Engineering Plastics,
Inc.
CONTACT
Edward H. Williams has a B.S. in Polymer Science from
The Pennsylvania State University, and is a 12 year
employee of LNP Engineering Plastics, a custom com-
pounder of engineering thermoplastics. His e-mail
address is Ed_Williams @ lnp.com. You can learn more
about LNP at their web site http:\\ www.lnp.com
Roderick E. Kleiss is President of Kleiss Gears, Inc. He
has a Masters degree in Mechanical Engineering from
Michigan Technological University. His e-mail address is
kleiss @ kleissgears.com. You can learn more about
Kleiss gears at their web site http://www.kleissgears.com
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Table 4. Mold Temperature and Measured Gear Dimensions (inches)
Material Mold Temp
(F)
Diametral
Pitch
Outside
Diameter
Root
Diameter
Pitch
Diameter
Tooth
Thickness
Base Circle
Diameter
K-1000 D 180 23.9440 1.1666 0.9731 1.0859 0.0637 1.0204
KL-4040 D 180 23.8340 1.1719 0.9792 1.0909 0.0644 1.0251
K-1000 180 23.9060 1.1663 0.9734 1.0876 0.0631 1.0220
KL-4410 180 23.8700 1.1692 0.9761 1.0892 0.0633 1.0236
KL-4040 180 23.8760 1.1699 0.9777 1.0890 0.0642 1.0233
KL-4540 180 23.8680 1.1694 0.9775 1.0893 0.0638 1.0236
Lubriloy K 180 23.8630 1.1688 0.9760 1.0896 0.0643 1.0238
Lubriloy KL 180 23.8820 1.1684 0.9758 1.0887 0.0636 1.0230
R-1000 180 23.7320 1.1775 0.9845 1.0956 0.0646 1.0295
RL-4030 180 23.8890 1.1701 0.9806 1.0884 0.0646 1.0227
Lubriloy RW 180 23.7820 1.1749 0.9802 1.0933 0.0645 1.0273
RA-1002 225 23.7440 1.1756 0.9807 1.0950 0.0636 1.0290
RAL-4022 225 23.6950 1.1779 0.9837 1.0973 0.0638 1.0311
RF-1006 225 23.3990 1.1915 0.9951 1.1112 0.0635 1.0442
RFL-4036 225 23.4170 1.1901 0.9934 1.1103 0.0632 1.0434
D-1000 100 23.2980 1.1978 1.0020 1.1160 0.0647 1.0487
DL-4030 100 23.3240 1.1965 0.9999 1.1147 0.0648 1.0475
Lubriloy D-EP 100 23.2940 1.1983 1.0015 1.1162 0.0649 1.0489
DF-1006 150 23.2570 1.2001 1.0037 1.1176 0.0646 1.0505
DFL-4036 150 23.2650 1.2012 1.0046 1.1176 0.0650 1.0502
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ASTM values on 0.125" thick parts
Gear Values on 0.150" thick parts
Table 5. Typical ASTM and Measured Mold Shrinkage Values (in/in)
Material ASTM
Flow
ASTM
Transverse
Gear Outside
Diameter
Gear Root
Diameter
Gear Tooth
Thickness
Gear Tooth
Height
Gear Base
Circle Diameter
K-1000 D 0.0210 0.0210 0.0324 0.0342 0.0202 0.0231 0.0336
KL-4040 D 0.0190 0.0210 0.0280 0.0282 0.0088 0.0270 0.0291
K-1000 0.0220 0.0180 0.0327 0.0340 0.0294 0.0263 0.0320
KL-4410 0.0220 0.0180 0.0302 0.0312 0.0261 0.0254 0.0306
KL-4040 0.0190 0.0210 0.0297 0.0297 0.0126 0.0298 0.0308
KL-4540 0.0180 0.0200 0.0301 0.0299 0.0189 0.0309 0.0305
Lubriloy K 0.0220 0.0210 0.0306 0.0313 0.0108 0.0267 0.0303
Lubriloy KL 0.0220 0.0210 0.0309 0.0316 0.0215 0.0276 0.0311
R-1000 0.0180 0.0150 0.0234 0.0229 0.0057 0.0261 0.0250
RL-4030 0.0150 0.0130 0.0296 0.0268 0.0066 0.0438 0.0314
Lubriloy RW 0.0190 0.0250 0.0255 0.0272 0.0078 0.0171 0.0270
RA-1002 0.0010 0.0018 0.0249 0.0266 0.0211 0.0164 0.0254
RAL-4022 0.0010 0.0011 0.0230 0.0237 0.0186 0.0197 0.0234
RF-1006 0.0040 0.0070 0.0118 0.0124 0.0231 0.0086 0.0111
RFL-4036 0.0030 0.0050 0.0129 0.0141 0.0281 0.0070 0.0118
D-1000 0.0080 0.0070 0.0066 0.0055 0.0043 0.0017 0.0068
DL-4030 0.0050 0.0070 0.0076 0.0076 0.0040 0.0076 0.0079
Lubriloy D-EP 0.0090 0.0070 0.0061 0.0060 0.0015 0.0067 0.0066
DF-1006 0.0010 0.0020 0.0046 0.0039 0.0071 0.0084 0.0051
DFL-4036 0.0024 0.0038 0.0038 0.0030 0.0002 0.0078 0.0054
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Table 6. Difference in Measured Gear Dimensions from Unlubricated Reference Materials (inches)
Material Outside Diameter Root Diameter Tooth Thickness Tooth Height Base Circle
Diameter
K-1000 D Reference
KL-4040 D +0.0053 +0.0061 +0.0050 +0.0007 +0.0047
K-1000 Reference
KL-4410 +0.0030 +0.0028 +0.0016 +0.0002 +0.0015
KL-4040 +0.0036 +0.0043 +0.0014 +0.0011 +0.0013
KL-4540 +0.0032 +0.0041 +0.0017 +0.0007 +0.0016
Lubriloy K +0.0026 +0.0026 +0.0020 +0.0012 +0.0018
Lubriloy KL +0.0021 +0.0024 +0.0011 +0.0005 +0.0010
R-1000 Reference
RL-4030 -0.0074 -0.0039 -0.0072 -0.0001 -0.0068
Lubriloy RW -0.0025 -0.0043 -0.0023 -0.0001 -0.0022
RA-1002 -0.0019 -0.0038 -0.0006 -0.0010 -0.0005
RAL-4022 +0.0005 -0.0008 +0.0017 -0.0008 +0.0016
RF-1006 Reference
RFL-4036 -0.0014 -0.0017 -0.0009 -0.0003 -0.0008
D-1000 Reference
DL-4030 -0.0013 -0.0021 -0.0012 0 -0.0012
Lubriloy D-EP +0.0005 -0.0004 +0.0002 +0.0002 +0.0002
DF-1006 Reference
DFL-4036 +0.0010 +0.0009 -0.0004 +0.0005 -0.0003
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