EXPERIMENTAL SETUP FOR EFFICIENCY EVALUATION OF LASER-CUT SPUR GEARS USING A MODULAR GEARBOX

Abstract

This paper presents the preparation and methodology for investigating the feasibility of using laser-cut spur gears in functional, low-load transmission systems. Six gear pairs with different transmission ratios, but identical center distances, were designed and manufactured using a laser cutting process. The focus was on achieving acceptable geometric accuracy and reliable meshing through a simplified and cost-effective production method. Each gear pair was mounted in a dedicated test module and prepared for future experimental testing using the GUNT AT200 apparatus. The test setup provides the capability for precise measurement of torque and rotational speed under controlled conditions, with multiple load levels and repeated trials planned to ensure data consistency. The main goal of this study is to establish a structured methodology and framework for evaluating the mechanical efficiency of laser-cut gears and to explore how gear ratio and geometry may influence performance. The study does not aim to directly compare laser-cut gears with conventional or industrial models, but rather to assess the potential applications of these simply manufactured gears as a cost-effective solution in suitable areas. This research lays the groundwork for future testing and analysis and is expected to contribute to the broader use of laser-cut gears in applications such as prototyping, education, and light-duty mechanical systems.