Bachelor's/Master's theses in the field of polymer use in high-speed systems

The mobility of the future requires innovative solutions to increase power density in drive systems. One approach to reducing vehicle weight while maintaining identical performance is to use high-speed engines (30,000 rpm) with low torques. These require an additional gearbox, but are so small compared with conventional engines that the overall weight of the vehicle is reduced. The high speeds and circumferential velocities give rise to numerous challenges that make the use of this technology difficult: the lubrication, cooling and bearing of the system must be adapted, noise and vibration effects arise, and the contact conditions in friction systems still need to be researched in depth.

To optimize such high-speed systems, IPEK is researching the use of lightweight materials as gear materials. Of particular interest is the use of polymers, which have already demonstrated their suitability for gears in numerous other areas: Polymer gears are easy to manufacture, have low density and integrated damping properties.

However, the use of polymers in an automotive gearbox has been unthinkable until now due to the high torques involved. At IPEK, we are investigating whether the reduced torques of a high-speed drivetrain make such an application not only theoretically conceivable, but also practically feasible. In particular, the investigation of the tooth contact in the high-speed toothing is the focus here.

For research on high performance polymers in use in high speed systems we are looking for final year researchers! The requirements are an independent and energetic way of working, creativity and good knowledge of MS-Office. Take advantage of this opportunity to expand your skills. If you are interested, we look forward to receiving your application.

Final thesis topics (subareas are also possible depending on your interests):

Investigations on plastic gears:

Analysis of constructive measures for gear construction in the field of high-speed.
Modeling and design of a plastic gear stage and analysis of the advantages regarding inertia and consumption (running)
Simulative analysis of plastic gears in the high speed range using FEM / MBS / ...
- Design of a shaft-hub connection for plastic high-speed gears (Completed)
- Influence of unbalance at high speeds and design measures
- Influence of tooth design
- ...
Testing the performance of the gearing on the test bench
- Design of test runs to investigate the influences of various parameters (gear design, lubricants, operating conditions...) on gear KPI and analysis of gears using digital microscope and coordinate measuring machine.

Design and construction of the high speed test rig:

Dimensioning and design of a burst protection system for high speed test bench (Completed).
Design of a test rig extension for lubricant testing (Completed)
Design and construction of a gearbox with quick change device for test gears (Completed)
Sensor technology at high speed test benches (esp. vibration investigations)
Design of a user-friendly user interface for the high speed test bench
Thermal model of the test rig for evaluation of the gear surface temperature during operation

Topic High-Speed & Plastics:

(Systematic) literature research on the above mentioned topics
Modeling in the context of high-speed systems (drives, clutches and transmissions)
Investigation of application areas and market potential of high-speed polymer gears (also for graduates in industrial engineering)

Profile:

Bachelor's or Master's student in the field of mechanical engineering, electrical engineering, computer science, physics or similar field of study
Interest in the research area of high-speed systems and gears
Interest in the research area of polymer engineering
Knowledge in Creo Parametrics (5), Windchill PDM (for constructive activity & drawing derivation), Matlab, Abaqus or further simulation software is desirable but not mandatory
Independent and conscientious way of working

Please send applications with application documents (incl. curriculum vitae and transcript of grades) to friedrich lagier ∂does-not-exist.kit edu.