Investigation of the durability and performance of autoclave-cured, woven carbon fiber-reinforced polymer composite gears in mesh with a steel pinion

Wear mechanisms and failure modes were investigated for autoclave-cured, woven carbon fiber-reinforced polymer (CFRP) composite gears in a mesh with a surface-hardened, 42CrMo4 steel pinion. The reference gears (m = 1 mm, b = 2 mm, z = 20) were tested at torque levels ranging from 0.4 Nm to 0.8 Nm. The temperature was monitored with a thermographic camera, while the gear damage and wear volume were analyzed and measured every 2 million cycles. The relationship between wear volume against the number of cycles was obtained. Scanning electron microscopy revealed two- and three-body abrasive, oxidative, and fatigue wear, and progressive de-laminations during the sliding and rolling of the gears. The CFRP composite gears exhibited higher wear resistance than the polymer ones.