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A joint development program between Metaldyne and Victrex Polymer Solutions was established with the goal of developing a cost effective net shape injection molded gear that provides improvements in NVH (Noise Vibration and Harshness) and operating efficiency over conventional high quality iron gears. A detailed DOE (Design of Experiments) evaluating NVH performance of machined gears was performed in a calibrated NVH test cell. Variables in the DOE included material, gear geometry and backlash variation. The DOE showed the PEEK material gears had different geometric sensitivities, such as helix angle effects, on NVH performance. The results of the DOE were then used to develop an optimal injection molded PEEK polymer gear design. A production quality injection molding gear tool was constructed. Net shape production quality PEEK polymer gears were injection molded and the gears were evaluated in a current production mass balance unit for NVH, mechanical efficiency and durability.

This paper presents results of two surveys, namely, a photographic measurements survey and a rider survey, conducted to determine how the type and origin of a motorcycle related to motorcycle dimensions, rider characteristics, seating posture, and motorcycle controls and displays. In the photographic survey, 12 most popular motorcycles covering three types (cruiser, sport, and touring) and three origins (Europe, Asia and North America) were measured from photographs taken in a standardized procedure with and without a rider. The data showed that the Asian and North American cruisers were very similar in all dimensions. These include seat height, seat to handlebar location, seat to foot rest location, foot rest size, and handgrip stance. This resulted in similar rider posture. North American sport motorcycles were more like cruisers than the Asian and European sport motorcycles.