This article presents a study of the joining of polyetherimide (PEI) polymer parts reinforced with fibre glass which has great application in the automotive sector. A simulation model based on the finite element method is proposed. For the modelling of the polymeric material, the three-network viscoplastic (TNV) rheological model was used, with very adequate results and producing a good fit with the experimental data. In addition, a methodology is proposed that allows simplifying a three-dimensional to an axisymmetric model, which implies a notable reduction in computational cost. In addition, the work includes an experimental analysis that evaluates the tightening torque under conditions of assembly repetitiveness, relaxation over time and influence of thermal cycles. These scenarios have a different influence depending on the geometry of the self-tapping screw used. Regarding repetitiveness, it has been verified that PF-30 (CELOspArk®) loses 17.16% while in Δ-PT (DELTA PT®) it loses up to 41.93% in the tenth repetition. In contrast, in the relaxation over time scenario, the PF-30 loses 13.38% and the Δ-PT loses 17.82%. Finally, regarding the thermal cycles, cooling allows to slightly delay the loss of tightening torque in both screws in a similar way; however, in the heating stage, 36.89% is lost with PF-30 and only 14.66% with Δ-PT. This study represents an improvement in the knowledge of the joining processes of self-tapping screws with polymeric materials of an engineering nature. The simulation model can be easily adapted to other materials and other geometries, and the experimental study offers a vision of the evolution of tightening conditions in realistic operating scenarios.

This study introduces a flexible methodology for the design and manufacturing of spiral bevel gears using five-axis NC machines, overcoming the rigidity of traditional methods. The innovation lies in the definition of customizable input parameters combined with the application of the Darboux trihedron to generate accurate and efficient toolpaths. The methodology integrates geometry generation, CAD modelling, and preliminary validation through additive manufacturing to improve collision detection and ensure feasibility. The experimental results, conducted on a five-axis machining centre, demonstrated the feasibility and high accuracy of the proposed approach. The solution enables the manufacturing of customized gears in different sizes, optimizes NC code generation by reducing code volume without compromising precision, and provides a robust alternative to commercial black-box software, offering greater control and adaptability for industrial applications.