In mechanical systems, different wear mechanisms can occur, including adhesive wear, abrasive wear, fatigue wear, fretting wear, erosive wear, and corrosion wear. Adhesive wear is the result of two surfaces sticking together and then tearing apart, causing material transfer between the surfaces. Abrasive wear, on the other hand, is caused by the sliding or impact of hard particles or asperities against a softer surface, resulting in the removal of material. These wear mechanisms can lead to the degradation of mechanical components and ultimately affect the performance of the system.
Adhesive wear differs from abrasive wear in that adhesive wear involves the transfer of material from one surface to another due to the surfaces sticking together and then tearing apart, while abrasive wear is caused by the removal of material due to the sliding or impact of hard particles or asperities against a softer surface. Both types of wear can lead to the deterioration of mechanical components, but they occur through different mechanisms and have different effects on the surfaces involved.
There are countless amazing stories that emerge from the manufacturing world—and Manufacturing Talks, hosted by Jim Vinoski, helps draw those stories into the light of day. As Jim states, "Manufacturing is where the rubber meets the road. There's no hiding. You're either making good products people will buy for enough to keep you in business, or you're not. Period." Nowhere is that more evident than in the gear industry. Check out Episode 51 with Matt Croson, President of the American Gear Manufacturers Association, sharing all about what the AGMA does.
Posted by on 2023-06-28
AGMA members descended on Fort Worth, Texas, from all corners of the country (and industry!) for three days of the 2023 Strategic Networking and Leadership Forum sponsored by Gleason Corporation, WD Bearings, Blaser Swisslube, and Specialty Steel Treating. Professionals from gear shops and OEMs alike gathered to share their experience and insight about where we are as an industry and where we're going.
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In this interview, we learn about Gleason Plastic Gears (GPG), a division of Gleason Corporation that specializes in designing and manufacturing plastic gears using their proprietary no-weldline technology. GPG has diversified its customer base and serves various industries such as automotive, medical, electronics, home and leisure, marine, education, and hobby. The interview covers topics such as the advantages of the no-weldline technology, surprising applications where plastic gears are replacing metal gears, promising materials and methods for the future of plastic gears, challenges faced by plastic gear designers, and recent developments in services, software, and manufacturing technology.
Posted by on 2023-04-04
State of the Gear Industry Perspectives takes an in-depth look at the challenges and opportunities in gear manufacturing today and in the future. Our seventh installment online is an interview with Kika Young, president, and Jared Lyford, director of manufacturing operations at Forest City Gear (FCG).
Posted by on 2023-02-13
Fatigue wear can occur in mechanical systems due to cyclic loading, which leads to the initiation and propagation of cracks in the material. Factors that can contribute to the occurrence of fatigue wear include the magnitude and frequency of the applied loads, the material's properties, and the presence of stress concentrations. Fatigue wear can lead to the failure of components, so it is important to consider these factors in the design and operation of mechanical systems to prevent fatigue wear.
Fretting wear occurs at the contact interface between two surfaces under small amplitude oscillatory motion. This type of wear is characterized by the formation of wear debris and surface damage, which can lead to material loss and ultimately affect the performance of the mechanical system. Fretting wear is often influenced by factors such as the applied load, relative motion, surface roughness, and environmental conditions.
Erosive wear is caused by the impact of solid particles or liquid droplets on a surface, leading to the removal of material. The main causes of erosive wear include the velocity and size of the particles or droplets, the angle of impact, and the properties of the impacted material. To prevent erosive wear, measures such as using protective coatings, altering the flow conditions, or using erosion-resistant materials can be implemented.
Lubrication plays a crucial role in reducing wear in mechanical systems by minimizing the friction and wear between moving surfaces. By providing a protective film between the surfaces, lubricants can prevent direct contact and reduce the occurrence of adhesive and abrasive wear. Proper lubrication selection and maintenance are essential for ensuring the longevity and performance of mechanical components.
Corrosion wear affects the performance of materials by causing the degradation and loss of material due to chemical reactions with the environment. Factors such as the presence of corrosive agents, temperature, and humidity can contribute to the occurrence of corrosion wear. To mitigate corrosion wear, protective coatings, corrosion-resistant materials, and environmental controls can be employed to prevent the degradation of mechanical components.
Various methods are used for analyzing lubricant film thickness in gearboxes, including optical interferometry, ultrasonic measurement, and capacitance measurement. Optical interferometry involves using light waves to measure the thickness of the lubricant film. Ultrasonic measurement uses sound waves to determine the thickness of the film. Capacitance measurement measures the dielectric properties of the lubricant to calculate film thickness. These methods provide valuable data for ensuring proper lubrication and preventing wear and tear in gearboxes. Additionally, advanced techniques such as infrared spectroscopy and atomic force microscopy can also be employed for more detailed analysis of lubricant film thickness.
Oil analysis can be a valuable tool in assessing the health of a gearbox. By analyzing the oil, experts can gain insights into the condition of the gearbox components, such as gears, bearings, and seals. This analysis involves examining various parameters, including viscosity, wear metals, contaminants, and additives. Viscosity measurements can indicate if the oil is still within the recommended range, which is crucial for proper lubrication. The presence of wear metals, such as iron, copper, or aluminum, can suggest the presence of abnormal wear or damage to the gearbox components. Contaminants, such as dirt or water, can accelerate wear and cause corrosion. Additionally, analyzing the additives in the oil can provide information about its ability to protect against wear and corrosion. By monitoring these parameters over time, oil analysis can help identify potential issues early on, allowing for timely maintenance and preventing costly breakdowns.
Screws and barrels are typically analyzed for thermal expansion using techniques such as finite element analysis (FEA), thermal imaging, and thermocouple measurements. FEA allows for the simulation of thermal expansion in the components by modeling their material properties and geometry. Thermal imaging can be used to visually observe the temperature distribution and expansion of the screws and barrels during operation. Additionally, thermocouples can be strategically placed on the components to directly measure the temperature changes and expansion. These methods provide valuable data for understanding how thermal expansion affects the performance and integrity of screws and barrels in various industrial applications.
Various solutions are available for dynamic sealing in gearbox systems. One commonly used solution is the use of lip seals, which are designed to provide effective sealing between rotating shafts and stationary housings. These seals typically consist of a flexible lip that comes into contact with the shaft, creating a barrier to prevent the leakage of lubricants and the ingress of contaminants. Another solution is the utilization of labyrinth seals, which employ a series of interlocking grooves to create a tortuous path for the fluid, thereby minimizing leakage. Additionally, mechanical face seals, also known as floating seals or duo-cone seals, can be employed in gearbox systems. These seals consist of two metal rings that are pressed together, creating a tight seal between the rotating and stationary components. Other solutions include O-rings, V-rings, and rotary shaft seals, each offering their own advantages and suitability for specific gearbox applications.
Filtration systems can be optimized for gearbox maintenance by incorporating various strategies and technologies. Firstly, the use of high-efficiency filters with fine mesh sizes and advanced media can effectively remove contaminants such as dirt, debris, and metal particles from the gearbox oil. Additionally, the implementation of bypass filtration systems can provide continuous cleaning of the oil, ensuring that it remains free from harmful particles. Furthermore, the integration of real-time monitoring and diagnostic systems can enable proactive maintenance by detecting any abnormalities or signs of wear in the gearbox. This allows for timely intervention and preventive measures to be taken, reducing the risk of unexpected breakdowns and extending the lifespan of the gearbox. Moreover, the utilization of automated filtration systems with self-cleaning capabilities can minimize manual intervention and optimize the efficiency of the maintenance process. Overall, by employing these optimized filtration systems, gearbox maintenance can be enhanced, leading to improved performance, reduced downtime, and cost savings.
Managing thermal issues in gearboxes requires careful consideration of several factors. One important consideration is the selection of appropriate lubricants with high thermal stability and heat dissipation properties. These lubricants should have low viscosity to minimize friction and heat generation. Additionally, the design of the gearbox should incorporate effective cooling mechanisms such as fins, heat sinks, or cooling fans to enhance heat transfer and prevent overheating. Proper ventilation and airflow within the gearbox housing are also crucial to dissipate heat. Furthermore, the material selection for gearbox components should prioritize heat resistance and thermal conductivity to withstand high temperatures and facilitate efficient heat transfer. Regular monitoring of gearbox temperature through temperature sensors and implementing preventive maintenance practices can help identify and address thermal issues before they escalate. Overall, a comprehensive approach that encompasses lubricant selection, cooling mechanisms, material selection, and monitoring is essential for effective thermal management in gearboxes.
When assessing screw shafts in barrel systems, there are several inspection guidelines that can be followed. Firstly, it is important to thoroughly examine the screw shaft for any signs of wear, such as abrasions, grooves, or pitting. Additionally, the inspector should check for any signs of corrosion or rust on the shaft. It is also crucial to inspect the screw threads for any signs of damage or deformation. Furthermore, the inspector should assess the overall condition of the screw shaft, including its straightness and alignment. Any deviations from the desired specifications should be noted. Finally, it is recommended to measure the dimensions of the screw shaft, including its diameter and length, to ensure they meet the required standards. By following these inspection guidelines, one can effectively evaluate the quality and performance of screw shafts in barrel systems.