The performance of plastic gears in wide variety of power and motion transmission applications is rather limited due to weak\r\nmechanical properties and divergent mechanism of failures. Amethodical simulation is carried out to analyze the gear performance\r\nwith various gating system types, gate locations, and processing parameters via grey-based Taguchi optimization method.With the\r\nobtained optimum results in simulation stage, the flow patterns of polymer melt inside the mould during filling, packing, and\r\ncooling processes are studied and the plastic gear failures mechanism related to processing parameters are predicted. The output\r\nresults in the future can be used as guidance in selecting the appropriatematerials, improving part and mould design, and predicting\r\nthe performance of the plastic gear before the real process of the part manufacturing takes place.
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