Running in heavy gears and

open gear drives

Frank Hohlbaum 1
 Content (1)

•tribological characterisation of heavy gears

•damage types
•damage a function of roughness
•achievable roughness levels
•definition “running-in“
•optimal roughness levels
•roughness, waviness
•specific aims of running-in

Frank Hohlbaum 2
 Content (2)

•running-in a prerequisite for

new gears
operated gear drives
•conditions
•mechanical influences
•choosing the suitable lubricant
oil lubrication
sprayable greases
•procedure of running-in
•duration of the process
Frank Hohlbaum 3
 Systematic approach

To analyse a given situation it is helpful to

look at a problem systematically

Try to strip every problem down and form a

“Tribological System“

Frank Hohlbaum 4
 Tribological system

Tribological System :
Stress Parameters
Environment
Counter body
Substance
Basic body

Surface Variation Material loss

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 Body and counter-body

what geometry ?

what material ?

what surface finish ?

what hardness ?

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 Technical characterisation of heavy gears

two or more meshing toothed gears

transmission of high starting torque's

pure rolling friction in the pitch point/line only

high proportion of mixed friction

defined microgeometry and structure of the

contact pattern

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 Failure boundaries
(schematical)
Wear boundary

Pitting boundary
External load

Tooth breakage boundary

Seizure boundary

Area of no failures

Circumferential speed
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 Damage areas

Different damage types not only form or shape the

tooth flank surface, but they originate from those
surfaces.

Harmful forces or strains attack the surface first, then

subsequently damages develop inside at a later stage.

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 Influence of surface finish (1)

Roughness effects

abrasive wear
(grooves are cut into the tooth surface)

wear caused by seizing

(roughness peaks weld to each other
under high load and low relative speed)

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 Roughness and seizing

When calculating the resistance to seizure, by using the

integral or flash temperature method, the surface
roughness - by the average local coefficient of friction -
is taken into account.

Reducing the flank roughness may double, or even

triple, the flank‘s resistance to seizure.

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 Roughness and seizing

Influence of
Specific scuffing load capacity pF (kp/cm)

Tests with

surface
roughness
Circumferential
speed v (m/s)
on the
specific
scuffing load
capacity
acc. Niemann and
Lechner

mild EP gear oil

Arithmetic middle roughness Ra (µm)
Ra in direction of
involute
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 Influence of surface finish (2)

Roughness effects :

formation of pitting
(by material fatigue due to permanently exceeding the
fatigue strength at roughness peaks)

the load carrying capability of tooth flanks

(the hydrodynamic pattern increases as roughness
decreases. Thus the load carrying area is improved)

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 Roughness and pitting

Pitting is initiated by small surface cracks, which become

larger in the length of time.
Pressurised oil is pumped into the crack at every gear
contact, and released again.
Thus the cracks enlarge and finally material is pealed off.

Preventing the formation of cracks could totally prevent

pitting formation.

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 Roughness and pitting

Side View

Top View

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 Destructive pitting on gear flanks

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 Note

Improved surface finish

achieved by

•smoothing
•shaping
•layer formation
•increase in strength

helps to prevent damages

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 Achievable roughness levels

depends on:

material strength
method of machining and finishing
type of gear
size of gear
gear modulus

medium roughness values Ra 0.4 to 3.2 µm

maximum roughness depth Rt 1.6 to 25 µm

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 Surface structure

combination of roughness, waviness and errors in shape

surface profile

roughness

waviness

error in shape

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 Definition “running-in“

chronological order / temporary sequence

change in shape
preparation for the anticipated service life

“Intentionally caused initial wear or surface rectification

on machine parts put into service“
such as
toothed gears
bearings
slideways

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 Running-in aims

to achieve „most favourable“ surface structure

to remove slight surface irregularities (micro range)

to establish an uniform and defined lubricant film

to achieve an optimum contact surface protection during

initial running hours

to assist in attaining a maximum load distribution and

surface contact area

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 Running-in

achieves „most favourable“ surface structure

high initial roughness causes plastic

deformation or abrasive wear

too low initial roughness causes particles to be torn out

of the friction surface by adhesive wear
(equilibrium principle)

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Running-in is useful for new gears, whenever

•new gears are put into operation

•gears are insufficiently produced
•surface finishing is economically limited
•gear size makes it impossible to optimise surface finish
•economical reasons require the use of second best
material
•economical reasons forbid optimal surface treatment

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Running-in is useful for used gears, whenever

•bearings have been repaired

•gears or part of gears have been re-aligned
•tooth flanks have been refurbished (e.g. grinding)
•individual transmission parts have been completely
renewed
•individual gears have been turned around

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 Basic preconditions for running-in

To successfully run-in gears

the mechanical conditions to which gear drives are
exposed during regular operation must be as favourable
and stable as possible
the optimum lubrication regime has to be ensured and
maintained during the whole process
all initial data concerning runouts, alignment and surface
conditions must have been filed
a credible concise monitoring and documentation of all
relevant data must be arranged during the whole process

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 Mechanical conditions / variables

Bearings:
clearance, tolerances, parallelity, alignment

Teeth:
static / dynamic clearance, load carrying area

Foundation:
stability, strength

Casing:
elasticity, stability
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 Mechanical conditions / variables

Deformation of machine structure:

by heat, static and dynamic load distribution,
misaligned bearings

Deformation of gear geometry:

by operational influences, torque application

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Change in load pattern by elastic deformation
due to torque distribution
Bending only Torsion only

MT

tooth deformation
Average value of

mation
defor-
Tooth
Torsion and Bending

average value deformation due to torsion

average value deformation due to bending
maximum tension deformation of pinion
maximum bending deformation of pinion

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 Specific requirements for running-in oils

provide max. resistance to seizure to avoid surface

damage
form rather thin oil film to allow specific wear

Running-in oils are:

of low base oil viscosity
equipped with specific anti-seizure additives
equipped with certain layer-forming additives
or equipped with plastic deformation additives

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 Possible additives in running-in oil

sulphur
phosphor
zinc
leaded soaps
molybdenum compounds

Additives are used in different ratios

and/or combinations

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 Oil lubrication running-in procedure

•disconnect bearings from oil circulation if abrasive

additives are included in the oil
•cleanse system with thin cleaning-oil
•fill running-in oil into system
•start gear system with approximately 50% load,
speed approximately 5 to 10 m/s
•limit load change number to below 200.000, to avoid
pitting formation
•check oil, bearings, noise & temperature

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 Oil lubrication running-in procedure

•gradually increase load while running in

•check oil after certain time
•change oil if necessary
•check load pattern in certain intervals
•when required condition is achieved rinse again, clean
filters and nozzles
•refill with service lubricant

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 Tooth flanks after a good running-in

Flender gear box of a Bucket Elevator

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Specific requirements for running-in greases

unlike oil lubrication only boundary lubrication!

provide maximum resistance to seizure to avoid
surface damage
form rather thin lubricating film to allow specific wear

Structure of Running-in greases:

base oil of lower viscosity
thermally stable thickener
specific anti-seizure additives
layer-forming solid lubricants
specific chemical reacting non-abrasive additives
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Running-in procedure Ball Mill Open Gear drive

1. Preparation
clean all tooth-flanks

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Running-in procedure Ball Mill Open Gear drive

1. Preparation
check initial condition of gears

alignment
clearance
tolerances
parallelity

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Running-in procedure Ball Mill Open Gear drive

1. Preparation
check run-out figures
Direct indicator gauge to measure
the axial (rim face) run-out

alternatively
Direct indicator gauge to
measure the axial float of
the mill

Direct indicator gauge to measure

the axial (rim face) run-out
Direct indicator gauge to measure
the radial run-out

Frank Hohlbaum 37
Running-in procedure Ball Mill Open Gear drive

1. Preparation
check run-out figures

•radial and axial run-out can be measured together

•the run-out limits are normally specified by the
equipment/gear manufacturer
•figures should be measured at 8 positions or more
•record measured data in one sheet

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 Running-in procedure Grease lubrication

1. Preparation
check alignment
Run-out limits for open gear drives of ball mills

1,6
1,4 ARO David Brown
Axial/Radial run-out

1,2 ARO Falk

1 ARO Polysius
0,8 RRO David Brown
0,6 RRO Falk
0,4 RRO Polysius
0,2 RRO FLS
0
2000 3000 4000 5000 6000 7000 8000 9000
Pitch circle diameter

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Running-in procedure Ball Mill Open Gear drive

1. Preparation
check run-out figures

•ensure that the jig is solid and not subjected to movement

•set up the gauge at the centre line (radial) or the centre of
a machined surface (axial) of the girth gear
•set the “0” dial to 5 mm
•use alligator clip to hold the pin back during movement
•before moving check always whether the pin is pulled
back

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Running-in procedure Ball Mill Open Gear drive

1. Preparation
check run-out figures

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Running-in procedure Ball Mill Open Gear drive

1. Preparation
check backlash and root clearance figures

•the recommended values are normally specified by the

equipment/gear manufacturer
•record data always with tooth number
•measure values with a feeler gauge always on both
sides of the flanks
•record measured data in one sheet

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Running-in procedure Ball Mill Open Gear drive

1. Preparation
check backlash and root clearance figures

Contact / Load
Root
face
clearance

Backlash

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Running-in procedure Ball Mill Open Gear drive

1. Preparation
check backlash and root clearance figures

Drive with a too large root clearance

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Running-in procedure Ball Mill Open Gear drive

1. Preparation
check backlash and root clearance figures

Backlash left Backlash right

side side

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Running-in procedure Ball Mill Open Gear drive

1. Preparation
check backlash and root clearance figures
Module Backlash
25 - 63 measured hot
Girth Gear Pinion Pinion Pinion
Pitch circle Pitch circle Pitch circle Pitch circle
diameter diameter diameter diameter
x 400 - 800 800 - 1600 1600 - 3200
(mm) (mm) (mm) (mm)
1600 - 3200 1,35 - 1,80 1,41 - 1,88
3200 - 6400 1,44 - 1,92 1,50 - 2,00 1,50 - 2,12
6400 - 12800 1,56 - 2,08 1,62 - 2,18 1,71 - 2,28
cold measured: increase all values at Ø < 6400 mm by 0,2 mm
xxxxxxxxxxxxxxxxxxxxxxxxx at Ø > 6400 mm by 0,4 mm
Recommended backlash values for Polysius ball mills

Frank Hohlbaum 46
Running-in procedure Ball Mill Open Gear drive

1. Preparation
check backlash and root clearance figures

•the pinion root to girth gear tip clearance and not the
gear root to pinion tip clearance should be measured
because it is smaller
•if tooth flanks are worn out the difference across the
tooth width of the contact / load face is more important
than the backlash
•there should be no clearance on the contact / load face

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Running-in procedure Ball Mill Open Gear drive

1. Preparation
apply high solid containing priming lubricant to provide
additional protection against initially seizure and overload

Qp = 2 x X x qmin x b x m x (Zg+ Y x Zri) [kg]

1000

Qp = Quantity of lubricant required (kg)

x = 2 to 2,5 (safety factor)
qmin = 0,15 (g/cm2) (specific quantity required/experience value)
b = tooth width (cm)
m = Module (cm)
Zg = Number of teeth on wheel
Zri = Number of teeth on pinion
Y = Number of pinions
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Running-in procedure Ball Mill Open Gear drive

Menge BERULIT 443

Quantity BERULIT 443
1000
60

900

50
800

Breite der Zahnflanken (mm)

Schmierstoffmenge (kg)
Lubricant quantity (kg)

700

Tooth flank width (mm)

40
600

30 500

400
20
300

10 200

100

0
1000 2000 3000 4000 5000 6000 7000 8000 9000

Teilkreisdurchmesser des Zahnkranzes (mm)

Pitch circle diameter girth gear (mm)

For a double pinion drive the quantity is to be multiplied by 1,15

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Running-in procedure Ball Mill Open Gear drive

1. Preparation

Right application of priming lubricant

Frank Hohlbaum 50
Running-in procedure Ball Mill Open Gear drive

1. Preparation
check spray system (volume, timing, pattern)

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Running-in procedure Ball Mill Open Gear drive

2. Control

use auxiliary drive to have the gear make slow revolutions

control and file initial condition

evaluate contact area and load distribution

without load by “Machining Blue” paste or
under load by oil resistant colour paint
to countercheck the alignment

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Running-in procedure Ball Mill Open Gear drive

2. Control

“Machining Blue” paste on the flanks of a gear

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Running-in procedure Ball Mill Open Gear drive

2. Control

“Machining Blue” paste on the flanks of a pinion

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Running-in procedure Ball Mill Open Gear drive

2. Control
Determination of unloaded contact pattern
• clean tooth flanks
• mix “Machining Blue” paste with degreaser or kerosene
• apply a thin film (approx. 6 to 12 µm) onto the pinion flanks
• rotate pinion and continue to apply mixture until a clear picture on
the girth gear flanks appears
• document the contact area at various positions by using an
adhesive transparent film tape
• multiple contact has to be avoided
• repeat the documentation at different stages of loading
Frank Hohlbaum 55
Running-in procedure Ball Mill Open Gear drive

2. Control

Prints of “Machining Blue” paste transmitted to paper

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Running-in procedure Ball Mill Open Gear drive
2. Control
Control of dynamic contact pattern by oil resistant colour paint
•clean the flanks and apply a 1 to 3 µm thick layer of the colour paint
(e. g. Relit Getriebeprüflack) on a grease free surface
•due to the content of highly inflammable solvent (flash point
approximately 15°C) smoking and open fire is strictly forbidden
•approximately 500 contacts are necessary to achieve a complete pattern
(by using a diluted lacquer approximately 200 contacts)
•500 contacts means approximately 2 to 4 minutes for a flank of a ball mill
pinion and approximately 30 minutes for a flank of ball mill girth gear
•longer running times falsify the result
•any start and stop of the mill during the test also gives wrong results
•comparable results can only be obtained if the mechanical conditions are
stable and the operating conditions (e. g. filling) are comparable as well
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Running-in procedure Ball Mill Open Gear drive

2. Control

Application of oil resistant colour paint

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Running-in procedure Ball Mill Open Gear drive

2. Control

Dynamic contact picture of oil resistant colour paint

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Running-in procedure Ball Mill Open Gear drive

3. Process
•load with appr. 60 % of mill balls
•continuos spraying of running-in grease
•only little charge of raw material
•check load pattern after 5, 15, 30 minutes by
using a stroboscope
•re-align if necessary
•continue until appr. 60 % load area is achieved
(50 - 200 hrs ), control every 12 hrs

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Running-in procedure Ball Mill Open Gear drive

3. Process
•load with appr. 80% of mill balls
•repeat procedure as before
•load with appr. 100% of mill balls
•repeat procedure as before

Normally after 2 weeks lubrication can be switched to

service lubricant and interval spraying

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Running-in procedure Ball Mill Open Gear drive

4. Monitoring
•changes in tooth flank temperature profile
•changes in tooth flank surface conditions
•changes in vibration level
•changes in dynamic contact conditions
•changes in bearing temperature

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Running-in procedure Ball Mill Open Gear drive

4. Monitoring
changes in dynamic contact conditions due to
•possible settlements of the foundation
•thermal effects (temperature of grinding material)
•addition of grinding material
•addition of grinding balls
•changes in applied power

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 Example of a good Running-in Process
Polysius Kiln gear drive, diameter 4650 mm, face width 450 mm

before Running-in
by BERULIT EL 420
10.05.2001

after Running-in
by BERULIT EL 420
17.05.2001
(some machinig
marks are still
visible)

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 Example of a good Running-in Process
FLS ball mill drive, diameter 6000 mm, face width 600 mm

After 4 days of Running-in

by BERULIT EL 420

After finishing the Running-in

process with BERULIT EL 420

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 Example of a good Running-in Process
KHD ball mill drive, diameter 5800 mm, face width 630 mm

After 3 days of Running-in

by BERULIT EL 420

After 6 days of Running-in

by BERULIT EL 420

Frank Hohlbaum 66
 Example of a bad Running-in Process
KHD Cement Mill gear drive

Bad contact pattern after

the running-in process

new pinions in contact

with a old worn out
girth gear

Frank Hohlbaum 67
 Example of a bad Running-in Process
KHD Cement Mill gear drive, diameter 5460 mm, face width 600 mm

Bad contact pattern and damages few weeks after the running-in process

strong single sided contact due to misalignment

(8 degree difference in flash temperature across the flanks)
Frank Hohlbaum 68
 Running-in Process general remarks

longer process under low load is preferable

additional start & stop procedure harms
avoid running-in under full load
normal consumption: 1 drum per pinion

Frank Hohlbaum 69
 Summary

optimum surface structure helps to increase

operational safety of large gear systems

surface roughness influences pitting formation, seizing

and micro-pitting

depending on size and finishing only certain

roughnesses can be achieved

Frank Hohlbaum 70
 Summary

defined running-in can be done with certain specific

running-in oils or greases

defined running-in means intentional limited abrasive

wear without seizing

thus an optimisation of surface roughness and load

pattern can be achieved

Frank Hohlbaum 71