Geometric Specification of Non-Circular Pulleys Made with Various Additive Manufacturing Techniques

The paper presents the procedure of generating geometrical features on the contours of non-circular pulleys through the selection of materials and technological parameters for easy and efficient production of these parts. Based on the models designed in the computer aided design (CAD) system, several prototype non-standard pulleys were made, which were assessed for functional characteristics and correct operation of non-linear gears. The effect of additive technology on the geometric specification of non-circular pulleys was also assessed. The results showed that thanks to the use of additive methods, the need for costly manufacturing of such wheels with subtractive methods was eliminated. Additionally, it is not necessary to design specialized cutting tools or to use conventional or numerically controlled machine tools to manufacture these wheels. The test results showed that in case of selective laser sintering (SLS) the highest accuracy of mapping (0.01 mm) of geometrical features of the surface was obtained. This result is confirmed by the assessment of the morphology of the surface of the teeth of gears made with this technique, characterized by a uniform structure of the working surface of the wheel while maintaining a high tolerance of the outer profile of gear for selective laser sintering at the level of ±0.03 mm. Research has shown that most of the additive methods used to manufacture non-circular pulleys meet the required geometrical features and due to the short production time of these pulleys, these methods also facilitate quick verification of the designed pulley geometry.