Common wear patterns observed on the soles of running shoes can provide valuable insights into a runner's gait and foot strike pattern. One common wear pattern is known as heel strike, where the outer edge of the heel shows significant wear. This suggests that the runner predominantly lands on their heel when running. Another wear pattern is called forefoot strike, characterized by wear on the front part of the shoe's sole. This indicates that the runner lands on the balls of their feet. Additionally, a wear pattern known as pronation can be observed, where the inner or outer edge of the shoe's sole shows more wear. This suggests that the runner's foot rolls inward or outward during the stride.
The wear pattern on the brake pads of a bicycle differs from that of a motorcycle due to the differences in their braking systems. In bicycles, the brake pads typically wear evenly across their surface, as the braking force is applied directly to the rim of the wheel. On the other hand, motorcycle brake pads often exhibit a taper wear pattern. This is because the braking force is applied to a disc rotor, which causes the inner part of the brake pad to wear more than the outer part. This taper wear pattern is a result of the caliper squeezing the brake pads against the rotor, causing uneven pressure distribution.
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.
Posted by on 2023-05-19
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
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 sixth installment online is an interview with Shane Hollingsworth, vice president of sales, Kapp Technologies.
Posted by on 2023-02-09
The rise of electrification is happening more widely and suddenly than anyone expected, both for automobiles and for other types of electric vehicles (EVs). The global EV landscape is also more competitive than the automotive markets of previous decades, as more manufacturers—large and small—compete for space. How can manufacturers stay ahead of the competition while also overcoming the increasing challenges posed by difficult-to-machine materials, like high-strength steel? A new all-directional tooling method, combined with the next-generation CoroTurn Prime B-type insert from Sandvik Coromant, holds the answer.
Posted by on 2023-02-08
The typical wear patterns seen on the teeth of a gear can provide valuable information about the gear's usage and condition. One common wear pattern is known as pitting, which appears as small, localized depressions on the gear teeth. Pitting is often caused by excessive loads or inadequate lubrication. Another wear pattern is called spalling, where small pieces of the gear tooth surface break off, resulting in rough and uneven surfaces. This can occur due to fatigue or material defects. Additionally, wear patterns such as scoring or fretting can be observed, indicating friction and rubbing between the gear teeth.
The wear pattern on the cutting edge of a knife can change with different cutting techniques. For example, when using a slicing motion, the wear pattern on the cutting edge tends to be more even and smooth. This is because the blade glides through the material, minimizing friction and reducing wear. In contrast, when using a chopping or rocking motion, the wear pattern on the cutting edge may become more uneven and jagged. This is because the blade experiences more impact and friction as it cuts through the material, leading to more localized wear and potential chipping.
Specific wear patterns observed on the tread of off-road tires can provide insights into the terrain and conditions in which they have been used. One common wear pattern is known as cupping or scalloping, where the tread blocks show uneven wear, resembling a series of cups or scallops. This can occur when the tire encounters rough or uneven surfaces, causing the tread blocks to wear unevenly. Another wear pattern is called feathering, where the edges of the tread blocks become rounded or worn down. This can be a result of prolonged use on abrasive surfaces or improper tire alignment.
The wear pattern on the clutch plate of a manual transmission differs from that of an automatic transmission due to the differences in their operation. In a manual transmission, the clutch plate experiences wear primarily during gear changes, as it engages and disengages with the flywheel. This can result in a wear pattern known as clutch plate glazing, where the surface of the clutch plate becomes smooth and shiny. On the other hand, in an automatic transmission, the clutch plates are constantly engaged and disengaged as the transmission shifts gears automatically. This can lead to wear patterns such as burnishing or hot spotting, where the surface of the clutch plate becomes discolored or glazed due to excessive heat and friction.
Characteristic wear patterns seen on the brake discs of a car can provide insights into the braking system's performance and condition. One common wear pattern is known as grooving, where the surface of the brake disc shows deep, parallel lines or grooves. This can occur when the brake pads wear down and the metal backing plate comes into contact with the disc, causing the grooves to form. Another wear pattern is called scoring, where the surface of the brake disc shows shallow, irregular lines or scratches. This can be caused by debris or contaminants on the brake pads or disc, resulting in localized wear. Additionally, wear patterns such as cracking or warping can be observed, indicating excessive heat or stress on the brake disc.
Temperature abnormalities in industrial gearboxes can be indicated by several key indicators. One of the primary indicators is an increase in the operating temperature of the gearbox. This can be measured using temperature sensors or thermal imaging cameras. Another indicator is the presence of abnormal heat patterns or hotspots on the gearbox surface, which can be detected through thermal imaging. Additionally, excessive noise or vibration in the gearbox can also be a sign of temperature abnormalities, as high temperatures can cause the lubricant to break down, leading to increased friction and wear. Other indicators may include changes in the color or consistency of the lubricant, as well as the presence of unusual odors or smoke. Monitoring these indicators and promptly addressing any temperature abnormalities is crucial to prevent damage to the gearbox and ensure its optimal performance.
Material losses in gearbox components are typically quantified through a combination of non-destructive testing methods such as ultrasonic testing, magnetic particle inspection, and dye penetrant testing. These methods allow for the detection and measurement of defects such as cracks, porosity, and material loss in gears, shafts, bearings, and other critical components. Additionally, advanced techniques such as vibration analysis and thermography can be used to assess the condition of gearbox components and identify any potential material losses. By utilizing these various testing methods, engineers and technicians can accurately quantify the extent of material losses in gearbox components, allowing for informed decisions regarding repair, replacement, or maintenance strategies.
Various strategies can be implemented to minimize friction in industrial gearboxes. One approach is to utilize high-quality lubricants that possess excellent viscosity and thermal stability properties. These lubricants can effectively reduce friction between the gear teeth and other moving components, thereby enhancing the overall efficiency of the gearbox. Additionally, the use of advanced surface coatings, such as diamond-like carbon (DLC) coatings, can further reduce friction by providing a smooth and low-friction surface. Proper alignment and precise manufacturing tolerances are also crucial in minimizing friction, as misalignment or excessive clearances can lead to increased friction and wear. Furthermore, incorporating efficient cooling systems can help dissipate heat generated by friction, preventing excessive temperature rise and potential damage to the gearbox components. Regular maintenance and inspection of the gearbox, including monitoring lubricant condition and replacing worn-out parts, are essential to ensure optimal performance and minimize friction-related issues.
To evaluate gearbox efficiency, several analyses are conducted. One of the primary analyses is the measurement of power loss in the gearbox. This involves calculating the difference between the input power and the output power of the gearbox. Another analysis is the measurement of torque loss, which involves comparing the input torque to the output torque. Additionally, the analysis of heat generation is important in evaluating gearbox efficiency. This involves measuring the temperature rise in the gearbox during operation. Furthermore, the analysis of vibration and noise levels can provide insights into the efficiency of the gearbox. By measuring and analyzing these various factors, engineers can assess the overall efficiency of a gearbox and identify any areas for improvement.
When it comes to lubricating gearbox bearings, there are several best practices that should be followed. Firstly, it is important to choose the right lubricant for the specific application. Factors such as temperature, load, and speed should be taken into consideration when selecting the lubricant. Additionally, the lubricant should have the appropriate viscosity and additives to ensure optimal performance and protection. Secondly, proper lubrication intervals should be established and adhered to. Regular inspections should be conducted to monitor the condition of the lubricant and bearings, and any signs of contamination or wear should be addressed promptly. Furthermore, it is crucial to apply the lubricant correctly. This involves ensuring that the bearings are clean and free from any debris before applying the lubricant. The lubricant should be applied in the right quantity and distributed evenly to ensure proper coverage. Finally, it is important to follow the manufacturer's recommendations and guidelines for lubrication. This includes using the recommended lubricant type and quantity, as well as following any specific instructions for application and maintenance. By following these best practices, gearbox bearings can be effectively lubricated to ensure optimal performance and longevity.
Non-contact measurement systems that are commonly used in gearbox maintenance include vibration analysis, thermography, and oil analysis. Vibration analysis involves the use of sensors to measure the vibrations produced by the gearbox, which can provide valuable information about the condition of the gears, bearings, and other components. Thermography, on the other hand, uses infrared cameras to detect and measure the heat generated by the gearbox, allowing technicians to identify potential issues such as overheating or excessive friction. Lastly, oil analysis involves analyzing samples of the gearbox oil to detect any contaminants, wear particles, or changes in viscosity, which can indicate the presence of problems such as excessive wear or contamination. These non-contact measurement systems play a crucial role in gearbox maintenance by providing valuable insights into the condition of the gearbox components, allowing for timely maintenance and preventing potential failures.
There are several solutions available for retrofitting gearbox components in order to improve their performance and extend their lifespan. One option is to replace worn or damaged gears with new ones that are made from more durable materials, such as hardened steel or ceramic. Another solution is to upgrade the lubrication system by installing a more efficient oil pump or using a synthetic lubricant that can withstand higher temperatures and provide better protection against wear and tear. Additionally, retrofitting can involve modifying the design of the gearbox to optimize its efficiency and reduce energy losses, such as by adding helical gears or improving the gear tooth profile. Furthermore, advanced technologies like condition monitoring systems can be implemented to detect early signs of component failure and allow for timely maintenance or replacement. Overall, retrofitting gearbox components offers a range of solutions to enhance their performance, durability, and reliability.
Gear tooth surface finishes in gearboxes are optimized through a meticulous process that involves various techniques and considerations. One crucial aspect is the selection of appropriate cutting tools and machining parameters, such as cutting speed, feed rate, and depth of cut. Additionally, the use of advanced grinding methods, such as honing and lapping, can further enhance the surface finish. The application of specialized coatings, such as diamond-like carbon (DLC) or nitriding, can also improve the wear resistance and smoothness of the gear tooth surface. Furthermore, the implementation of proper lubrication systems and the use of high-quality lubricants play a vital role in reducing friction and minimizing surface roughness. Overall, a comprehensive approach that combines precise machining techniques, advanced coatings, and effective lubrication strategies is essential for achieving optimized gear tooth surface finishes in gearboxes.