Image-based monitoring of material emissions for wear characterization of laminated polymer composite gears

Durjava, Aleš (author), Mojškerc, Bor (author), Bergant, Zoran (author), Vukašinović, Nikola (author)

This work presents a computer vision image-based methodology for quantitative wear particle diagnostics in polymer composite gear systems. Conventional monitoring techniques typically provide limited information on the morphology and size distribution of the particles, restricting their diagnostic capability. In this study, optical microscopy is combined with computer vision image-based algorithms to characterize particles resulting from gear wear. Inspection at magnification captured approximately 70 % of the microplastic range, while complementary SEM analysis at confirmed extended diagnostic capability at sub-micrometer scales. The circularity and aspect ratio of particles proved to be important indicators of wear stages, while the size of the particles remained consistent regardless of the torque applied. Approximately 80 % of the worn out volume was found consistently represented by 10–50 particles. The developed methodology provides reproducible and quantitative insights into gear wear stages that are not accessible through conventional monitoring. The results demonstrate potential for improved monitoring and reliable failure prediction in polymer composite tribosystems.

• Language: English
• Keywords: wear, gears, composites, microplastics, particles, image analysis
• Work type: Article
• Typology: 1.01 - Original Scientific Article
• Organization: FS - Faculty of Mechanical Engineering
• Publication status: Published
• Publication version: Version of Record
• Year: 2026
• Number of pages: 10 str.
• Numbering: Vol. 590, art. 206563
• PID: 20.500.12556/RUL-179442
• UDC: 621.833:620.17:004.932
• ISSN on article: 0043-1648
• DOI: 10.1016/j.wear.2026.206563
• COBISS.SI-ID: 268425219
• Publication date in RUL: 13.02.2026

Record is a part of a journal

• Title: Wear
• Shortened title: Wear
• Publisher: Elsevier
• ISSN: 0043-1648
• COBISS.SI-ID: 5374213

Licences

• License: CC BY-NC-ND 4.0, Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International
• Link: http://creativecommons.org/licenses/by-nc-nd/4.0/
• Description: The most restrictive Creative Commons license. This only allows people to download and share the work for no commercial gain and for no other purposes.

Secondary language

• Language: Slovenian
• Keywords: kompozitni zobniki, obraba, zobniki, kompoziti, mikroplastika, delci, analiza slik

Projects

• Funder: ARIS - Slovenian Research and Innovation Agency
• Project number: P2-0425
• Name: Decentralizirane rešitve za digitalizacijo industrije ter pametnih mest in skupnosti

• Funder: Other - Other funder or multiple funders
• Funding programme: European Union - NextGenerationEU
• Name: GREENTECH: developing the factories and products of the future for the green transition