Analysis of Sprocket Strength and Deformation for Metallic and Composite Polymer Materials

Abstract

This paper is a comparative static structural analysis of a sprocket designed in Solid Edge 2025 (Student Edition) and a structural analysis performed by ANSYS R2 2025 (Student Version) using Finite Element Analysis (FEA). The aim is to measure and contrast the behavior of three different materials, which are C45 carbon steel, PA66-GF30 (glass-fiber reinforced nylon) and Kevlar-49 polymer composite, under the same loading conditions. The parameters under analysis are total deformation, von Mises stress, mass, and volume, to determine which material is most suitable for the application of sprockets. These findings show that C45 steel exhibits the least deformation and the greatest stiffness, confirming its current leadership in conventional sprocket production. Nevertheless, the factors of significant mass and volume reduction are observed in both PA66-GF30 and Kevlar-49 composites, which provide lightweight alternatives with acceptable and moderate deformation increase. Kevlar-49 is the best mechanical performance of the composite materials and it is the one with the best strength to weight ratio, and could therefore be promising in the applications where less weight is required without significant loss in strength or rigidity. Although they offer structural benefits, composite designs such as PA66-GF30 and Kevlar-49 have weaknesses in wear resistance and wear surface, and thus may limit their durability under heavy contact, sprocket system applications. The report addresses possible ways of curbing these disadvantages such as surface coating, optimization of lubrication, and hybrid material designs. In general, the present comparative analysis has indicated the possibility of substituting the traditional metallic sprockets with innovative composite materials in lightweight mechanical systems, as long as the issue of wear surface is adequately controlled.