Fiber Reinforced Plastic (FRP) gears
Composite gears are designed as a combination of metal and fiber reinforced plastic for higher performance and reduced weight. We have done design, prototyping and transition into production of composite mechanical components since 1978.
This composite gear is 2020 SBIR proposal for US Army effort to replace large Main Rotor Gear Box (MRGB) spiral bevel ring gears with FRP composite alternative for weight and cost reduction. Often helicopter MRGB (EC225, CH47, S97, OH-58, A160, Mi-8) incorporates a large spiral bevel gear that that is very expensive if not impossible to make as one part. The idea is to make FRP rim connecting the smaller size hub with the ring gear. Spiralbevel.com proposal incorporated a filament wound rim with fibers places around multiple design elements located on the perimeters of the hub and the ring gear. The proprietary filament winding pattern on the 3d model is cosmetically shown as carbon fiber twill cloth.
OH-58 MRGB
Subject gear is red-lined
Proposed FRP composite gear
Metal parts of the gear
Previous FRP composite projects.
The main advantage of FRP gears is the possibility to design previously impossible mechanical components with previously impossible low cost. Composite gears could be the next big thing in the industry of mechanical components after 5-axis CNC gear tooth machining. On the projects shown below the cost reduction was 2 times or better with significant weight saving. Composite gears are particularly beneficial for new start-ups because of lower capital investment. FRP composite manufacturing equipment is lower cost compared to the traditional metal working machines. The modern advancement in software development and robotics makes it easier to automate. FRP manufacturing does not produce waste. FRP material current cost is 4 times less compared to 10 years ago and it continues to decline. FRP material mechanical properties continue rapid improvement.