GEAR FAILURE MODES
Tanslated from Edgar Espero Mora y Juan Carlos Martinez Romero, Universidad Nacional de Colombia, September 2011
DUCTIL FRACTURE
Presence of shear of the tooth
accompanied by a large plastic
deformation.
SOME CAUSES
- Overload due to high torque
Hardness of the surface layer and / or
low gear core.
- Low thickness of the hardened
layer.
- Absence of hardened layer.
WEAR
ABRASIVE WEAR
When the tooth surface of a gear is
machined or polished in service.
SOME CAUSES
- Lubricant with particles.
- Low viscosity or high torque.
- Low speed.
Hardness in hardened layer.
- High hardness difference between
the coupled gears.
SUPERFICIAL FATIGUE
PITTING
This is a localized loss of material,
usually in the form of small cavities.
SOME CAUSES
- Low hardness in the hardened layer.
- Low viscosity of the lubricant.
- Continuous operation torque higher
than recommended.
* EP: Extreme pressure additives
- Absence or deficiency of EP *
contained in some lubricants
additive in the lubricant.
MACRO-PITTING OR UNLOADING
Serious pitting, in which large
pieces of material come off the
surface.
SOME CAUSES
Hardness at heart and / or low
hardness layer and / or insufficient
thickness thereof.
- The same things as pitting but
more serious.
CRACKING
CRACKS FACING TEETH
Initial phase of partial tooth loss due
to fatigue.
SOME CAUSES
- Inadequate surface condition of the
teeth.
- Cracks can start from macro-pitting.
See also the causes of total or partial tooth
breakage due to fatigue.
CRACKS IN THE ROOT AREA
Initial stage of total or partial tooth
crack due to ductile, fragile or fatigue
fracture.
SOME CAUSES
See also the causes of total or partial
tooth breakage.
IRREGULAR GEARS RISK FACTORS
STRESS CONCENTRATION
The gear shows signs that the
entire side of the tooth is not
working evenly.
CAUSES: Misalignment of shaft
In this case the stress deflection, deformation due to
concentration will promote heat treatment, improper
macro-pitting. machining or assembly, etc.
CONSEQUENCES: Accelerates
the failure mechanisms
described in this guide.
PARTIAL OR TOTAL FRACTURE OF THE TOOTH
FRAGILE FRACTURE
Fracture of granular aspect brilliant
and without apparent plastic
deformation.
SOME CAUSES
- Overload due to high torque.
Hardness of the hardened layer and /
or high toothing.
- High thickness of the hardened
layer.
GEOMETRIC DEFORMATION OF THE TOOTH
WEAR
ADHESIVE WEAR
When the metal is transferred between
two gears, because they come in direct
contact because the lubricant layer
breaks.
SOME CAUSES
- Deficiency of EP * additives.
Hardness in hardened layer.
- High speed or temperature.
*EP : Additifs de pressions extrêmes - Low viscosity or high torque.
contenus dans certains lubrifiants
- Failure of the lubrication system.
PLASTIC DEFORMATION IN THE ROOT AREA
CREASE
It has the form of waves or ladders
perpendicular to the sliding direction.
SOME CAUSES
- Low viscosity of the lubricant.
- Continuous operation torque higher
than recommended.
- Absence or deficiency of EP *
* EP: Extreme pressure additives additive in the lubricant.
contained in some lubricants
DEVELOPMENT OF SILLONS
The grooves follow the direction of
sliding on the surface of the tooth.
SOME CAUSES
- Low viscosity of the lubricant.
- Continuous operation torque higher
than recommended.
- Low speed.
* EP: Extreme pressure additives - Absence or deficiency of EP * additive in
contained in some lubricants the lubricant.
CRACKS IN THE CENTER OR ON THE EDGES
The cracks start at the foot of the
tooth and go to the center of the
tooth. Usuallly formed by fatigue.
SOME CAUSES
- Inadequate design due to the
thinness of the border.
CRACKS IN THE DISCONTINUITIES
Fatigue cracks are normally formed in the
lubrication holes, shim housings, grooves,
lightening holes or other concentrators.
SOME CAUSES
- Holes, wedges, grooves, etc., poorly sized
- High overload or continuous operation
torque higher than recommended.
INTERFERENCE
In the root arae, there is
abnormal wear generated during
operation.
CAUSES: Reduced number of
teeth, misalignment, high radial
pressure between the gears.
CONSEQUENCES: Accelerates the
failure mechanisms described in
this guide.
FATIGUE
Progressive fracture that spreads
Elliptical fatigue striations during the work of the gear. Its
surface is smooth and normally has
concentric elliptical marks at the
origin.
SOME CAUSES
- Continuous operation torque higher
than recommended.
Hardness at heart and / or layer with
little hardening and / or insufficient
Origin
thickness.
CORROSION
CORROSION
Deterioration of the surface by
chemical action, or pitting and / or
deposits on the teeth.
SOME CAUSES
- Contamination of the lubricant with
chemicals or water.
- Absence or deficiency of
The attack can be generalized anticorrosive additive.
by concentration gradient or - Mix the oil marks.
slit; with uniform or puncture - Use a lubricant that is not suitable
mechanism. for bronze gears.
PLASTIC DEFORMATION IN THE TOP AREA
NOTCH
Due to a foreign body that is caught
in the mating of teeth and destroys
its profile during operation.
SOME CAUSES
- Presence of foreign elements
between the gears.
- Consequence of tooth fracture or
macro-pitting.
FLATTENING, SHARPENING AND RETRACTION
Deformation of the teeth resulting in
triangular shapes and / or lateral flow
generating chips.
SOME CAUSES
- Low viscosity and / or speed.
Hardness at heart and / or layer with
little hardening and / or insufficient
thickness.
- Continuous operation torque higher
than recommended.
RISK FACTORS
OVERHEATING
The affected teeth or area have a
range of colors. Yellow (200 ° C), Blue
(300 ° C) and Dark Brown DD (400 ° C)
approx***.
SOME CAUSES
- Leads quickly to adhesive wear.
- The lubricant is degraded and the
*** The maximum operating
temperatures of the lubricants other failure mechanisms described
vary between 85 ° C and 120 ° C in this guide are accelerated.
PROBLEMS IN RECONSTRUCTION
Because of the dimensional accuracy,
surface treatment, hardness and chemical
composition of the steels used in the gears,
it is not advisable to repair them by
welding.
SOME CONSEQUENCES
- Dimensional differences.
- Hardness less than required.
- Accelerates the failure mechanisms
described in this guide.
GENERAL CONSIDERATIONS
- In the case of gears, choose the material, the thickness of the hardened layer, the
hardness, the dimensions, the tolerances and the finishes of the toothing, as
specified by the specialized standards such as ISO.
- When replacing gears, it is best to do it in pairs.
- Misalignment, tightness or excessive play between the gears will accelerate the
appearance of the failure mechanisms described in this guide.
- Use the appropriate viscosity, additive group and type of lubricant in each case
according to the equipment manufacturer's recommendations.
- The described failure mechanisms result in vibration, noise and heat which, if
detected in time, can prevent catastrophic property damage or injury to the
operator.
- Sensitize operators, drivers and users in general to the importance of avoiding
overloading the equipment under their load by torque and / or speed and / or
impacts.
- The common causes of the failure modes described here are only a general guide,
since each case of failure must be analyzed in a particular way to find other possible
causes.
- Under appropriate lubrication and loading conditions, that is, when proper
maintenance and operating procedures are followed, the service life of the gears is
conditioned by surface fatigue.
When oils of different brands are mixed, corrosive compounds can be generated by
reaction between incompatible additives.