Detecting shrinkage voids in plastic gears using magnetic levitation

Shrinkage voids have a large influence on the quality of plastic gears, and it is still a problem to detect the voids inside gears accurately and conveniently. This paper presents a novel method for detecting shrinkage voids via magnetic levitation. The porosity levels of plastic gears can be calculated using magnetic levitation because the density of plastic gears is influenced by the shrinkage voids. The distribution of shrinkage voids is quantified by the moment of volume, hence a theoretical model for the distributions of shrinkage voids and levitating posture can be established. Computer tomography (CT) detections were also carried out to verify the accuracy of magnetic levitation for detecting the shrinkage voids. Experimental results show that the average relative error of calculated porosity level is less than 7%, and the theoretical model for distribution of shrinkage voids agrees well with the results from CT detections, with the correlation coefficient being up to 99.8%. The proposed method has great potential for mass detection of plastic gears. © 2020 Elsevier Ltd