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Klaus Michaelis
Chief Engineer
Institute for Machine Elements
Gear Research Centre (FZG)
Technische Universitat
Munchen, Germany
The good news is there are only five common failure modes:
bending fatigue, pitting, micropitting, scuffing, and wear.
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gear rim.
Micropitting is a relatively recent phenomenon that has Fracture surface due to bending fatigue of a case-
become more prevalent owing to an increased use of carburized gear tooth (top) and a nitrided tooth
surfacehardened gears (case carburized, nitrided) made of (bottom).—Labs, Dept. Mech. Engr, PoliMI
better-quality, cleaner steel. Modern lubricants with
sophisticated additive packages that let gears work in more
extreme conditions may indirectly contribute to micropitting.
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In any case, lubricant and lubricating conditions, not material Bending fatigue failure with beach marks.—FZG, TU
strength, are responsible for scuffing damage. Scuffing often Munchen, Germany
happens to new gears when tooth surfaces are not yet well
run-in. Experiments show that a newly manufactured surface is
able to carry only 20% of the load of a well run-in surface. The
risk of scuffing goes up as lubricant degrades over time or
becomes contaminated with metal particles or water. It is
sometimes difficult to distinguish between surface scratches
from instantaneous scuffing or those from wear.
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Scuffing
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Wear
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