Value engineering: timing-belt pulley

An aluminium/steel timing-belt pulley was analysed using the Value Engineering method. A 55% reduction of the cost price was achieved by integrating components and selecting the optimal materials. Result: plastic teeth moulded around a steel shaft with straight knurl.

Production techniques: plastic injection moulding, machining
Delivery: moulds, products

Complexity caused by: load in combination with necessary precision of tooth shape at temperatures of -15 to 70°C, required lifespan of 1,000,000 cycles. Tested using FEM analysis.