Evaluation of load‐carrying and wear resistance of carbon‐reinforced composite gears for <scp>E</scp>‐mobility: Short‐term versus long‐term performance

Abstract A systematic approach to examining the tribological contact between a steel and a composite gear composed of polyamide 66 reinforced with 20% short carbon fibers is shown in the paper. Over a wide torque range, a detailed study of fatigue testing steel/composite gear pairs is provided. To examine the impact of carbon fibers on the gear pair's wear parameters, tests were also conducted on base polyamide 66 for comparison. The composite gear's wear behavior throughout the course of its lifetime was examined and connected to the contact's temperature response. The findings show that, in comparison to generic polyamide 66, the carbon fibers in the polyamide 66 matrix lower the friction coefficient by 39%. When wear of the gear pair is noticed, the advantages of carbon fibers become much more apparent. On average, the wear coefficients of composite gears are 73% lower than those of polyamide 66 gears. The fact that the composite gears have a substantially longer lifespan than regular polyamide 66 gears further supports this claim. Highlights Carbon fiber reinforcement enhances the fatigue life of polyamide 66 gears by up to 86%. Composite gears exhibit a 39% reduction in friction compared to steel/polyamide 66 contacts. The wear coefficient of carbon‐reinforced polyamide 66 is 73% lower than that of standard polyamide 66. Carbon fibers reduce friction and heat generation, preserving material properties over time. Carbon reinforcement improves bending strength and reduces strain, enhancing drivetrain performance.