SAF87 - Y3.0KW - 166 The main reasons for gear damage of reducer are as follows:
Overload : The equipment is subjected to loads exceeding the gear design capacity of the reducer gear during operation, such as long-term high-load operation, sudden large-load impact, etc., which will aggravate the wear of the gear tooth surface, and cause fatigue fracture or deformation.
Lubrication issues :
Lubricant oil pollution : tiny particles such as impurities, dust, metal chips are mixed into the lubricant. These particles enter the gear meshing area and will cause wear on the tooth surface like abrasives, and may also scratch the tooth surface.
Oil shortage or poor oil quality : Failure to replenish lubricant in time leads to insufficient oil quantity, or poor quality, inappropriate viscosity, deterioration, etc., will prevent a good oil film from forming between the tooth surfaces, increase friction, and cause damage to the tooth surface.
Water inlet into the oil : Moisture enters the lubricating oil will reduce the lubricating performance of the oil, which may also cause rust and corrosion of the gears, which will affect the normal operation and life of the gears.
Installation and assembly issues :
Poor shaft centering : During the installation of the reducer, if the shaft centering with the drive motor or other connected equipment does not meet the specification requirements, the gears are subjected to uneven stress and locally under excessive load. At the same time, it may also be accompanied by impact, and long-term operation will cause fatigue damage to the tooth surface.
Inadequate installation accuracy : installation errors such as the gear axis is not parallel and the center distance is inaccurate, which will cause the gear to not mesh correctly during operation, resulting in biased load and additional wear, affecting the service life of the gear.
Materials and Manufacturing Defects :
Material quality problems : The gear material itself has defects, such as containing impurities, sand holes, pores, insufficient strength, or insufficient ductile ductility, etc., which will cause the gear to be easily damaged such as wear, cracks and even breaking under normal working loads.
Improper heat treatment : The gear heat treatment process is not well controlled, such as insufficient hardness, uneven thickness of the carburized layer, and internal stress, which will reduce the wear resistance, fatigue strength and other properties of the gear, resulting in premature damage to the gear.
Low machining accuracy : During the processing of gears, due to limited process level or insufficient equipment accuracy, the gear's tooth shape, tooth direction and other accuracy are not met, resulting in poor meshing of gears, increasing the uneven stress and wear of gears.
Long-term fatigue operation : After a long period of repeated loading and unloading, the gears are subject to alternating stress, and fatigue cracks are easily generated at the roots of the teeth. Over time, these cracks gradually expand, which may eventually lead to the gear breakage or the tooth surface peeling.
Foreign objects enter : impurities, dust, metal debris and other foreign objects enter the gear meshing area, which will not only cause wear and scratches on the tooth surface, but may also affect the normal meshing of the gear, causing the gear to be subjected to additional impact and friction, which will in turn lead to gear damage.
Impact load : Suddenly encounter shock or violent vibration during operation of the equipment, such as impact when the motor starts or stops, vibration caused by equipment failure, etc., which causes the gear to be subjected to excessive force instantly, which can easily cause damage to the gear tooth surface and breakage of the teeth.
