GEAR BOX

FAILURE ANALYSIS

ALI HASNAIN
ENGINEER MECHANICAL
GEAR BOX FAILURE ANALYSIS
 GEAR BOX FAILURE ANALYSIS

MECHANISMS LEADING TO
GEAR BOX FAILURE

 GEARS FAILURE MECHANISM

 SHAFTS FAILURE MECHANISM
 BEARINGS FAILURE MECHANISM
 SEALS FAILURE MECHANISM
 GEAR BOX FAILURE ANALYSIS

GEAR FAILURE MECHANISM

 SURFACE FATIGUE
 PITTING
 SPALLING
 WEAR
 PLASTIC FLOW
 BREAKAGE
 GEAR BOX FAILURE ANALYSIS

ANTI-FRICTION BEARING FAILURE

MECHANISM

 CORROSION
 CONTAMINATION OF THE LUBRICANT
 OVERHEATING
 INADEQUATE INTERNAL CLEARANCE
 UNEXPECTED VIBRATORY LOADS
 MISALIGNMENT
 INADEQUATE LUBRICATION
 GEAR BOX FAILURE ANALYSIS

CONTACT OIL SEALS FAILURE CAUSES

 DAMAGE IN HANDLING OR
MOUNTING
 HARDENING AND CRACKING DUE TO
HEAT OR CHEMIC ALATTACK
 IMPROPERLY PREPARED OR DAMAGED
SHAFT JOURNAL
 GEAR BOX FAILURE ANALYSIS

SHAFT FAILURE CAUSES

 TORSIONAL FRACTURE
 BENDING FRACTURE
 KEYS AND KEYWAYS
 FRETTING CORROSION
 GEAR BOX FAILURE ANALYSIS

GEAR FAILURE MECHANIS

 SURFACE FATIGUE: Failure of a material due to repeated
surface or sub-surface stresses beyond the endurance Limit.
(Fingure's example)

 Pitting & Spalling are examples of surface fatigue.

 GEAR BOX FAILURE ANALYSIS

GEAR FAILURE MECHANIS (PITTING)

 PITTING: Initial (corrective), destructive & normal.

 INITIAL PITTING:
• Caused by local areas of high stress due to uneven surfaces.
• Develop within a relatively short time, reach a maximum
and with continued service to a lesser severity.
• Develop in a narrow band at the pitchline or just slightly
below the pitchline.
• Prominent in through hardened gears as compared to
surface hardened.
 GEAR BOX FAILURE ANALYSIS

GEAR FAILURE MECHANIS (PITTING)

(INITIAL PITTING)
 GEAR BOX FAILURE ANALYSIS

GEAR FAILURE MECHANIS (PITTING)

 DESTRUCTIVE PITTING
• Starts below the pitch line, in the dedendum portion.
• Progressively increases in size and number of pits.
• Surface is destroyed.
• Results from surface overload conditions that are not
alleviated by initial pitting.
• Causes are Misalignment,
Eccentricity, Bend Shaft etc.
 GEAR BOX FAILURE ANALYSIS

GEAR FAILURE MECHANIS (PITTING)

Through Hardened Gear Vs Surface Hardened Gear

Destructive Pitting
 GEAR BOX FAILURE ANALYSIS

GEAR FAILURE MECHANIS (PITTING)

 NORMAL DEDENDUM PITTING (DEDENDUM WEAR)
• Small or modest size pits, covering the entire dedendum
portion of the tooth flanks.
• Not progressive, pit rims found worn away.
• Dedendum is vulnerable to this phenomenon because of the
preferential orientation of the surface microcracks.
• In dedendum, oil
is trapped due to
sliding contact, in
addendum oil is
forced out of cracks
 GEAR BOX FAILURE ANALYSIS

GEAR FAILURE MECHANIS (SPALLING)

 SPALLING:
• A large chunk of area is removed.
• The visual pit like attributes are not observed.
• Bottom of the spall appears to run along the case-core
interface.
• Causes are surface or subsurface defects or excessive
internal stresses from improper heat treatment.
 GEAR BOX FAILURE ANALYSIS

GEAR FAILURE MECHANISM (WEAR)

 WEAR: Measured in terms of thousandths of an inch per
million or 10 million contact cycles.

 POLISHING OR LIGHT WEAR

• Very slow process hence will not effect the life of gear.
• Sharpness of the contacting surfaces are gradually worn until
very fine.
• Can occur by either abrasive or adhesive mechanisms due to
boundary lubrication or viscosity issues of oil.
 GEAR BOX FAILURE ANALYSIS

GEAR FAILURE MECHANISM (WEAR)

 MODERATE WEAR
• Progresses at a rate slow enough that it will little affect
performance of the gears.
• Tooth contact patterns indicates metal removal.
• Operating pitch line begins to show as an unbroken line.
• The limitations of usable oil viscosities and the speed
requirements are to prevent moderate wear.
• Gears must not operate in the boundary lubrication regime
where metal-to-metal contact occurs and wear takes place.
 GEAR BOX FAILURE ANALYSIS

GEAR FAILURE MECHANISM (WEAR)

Light Wear Moderate Wear

 GEAR BOX FAILURE ANALYSIS

GEAR FAILURE MECHANISM (WEAR)

 EXCESSIVE OR DESTRUCTIVE WEAR:
• Surface destruction changes the tooth shape to large extent.
• Smoothness of meshing action is impaired and life is
appreciably shortened.
• Continued operation results in still greater wear and may
eventually lead to tooth breakage.
• Excessive loads, contaminated oil or too light an oil viscosity.
 GEAR BOX FAILURE ANALYSIS

GEAR FAILURE MECHANISM (WEAR)

 WEAR MECHANISM: ABRASIVE WEAR, ADHESIVE WEAR
• ABRASIVE WEAR: sometimes called cutting wear occurs
when hard particles slide and roll under pressure, across the
tooth surface.
• Dirt in the housing, sand or scale from castings, metal wear
particles from gear teeth or bearings.
 GEAR BOX FAILURE ANALYSIS

GEAR FAILURE MECHANISM (WEAR)

• ADHESIVE WEAR: Results from high attractive forces of the
atoms composing each of two contacting, sliding surfaces
• The junction area grows until a particle is transferred across
the contact interface.
• In subsequent encounters, the transferred fragment fractures
or fatigues away, forming a wear particle.
 GEAR BOX FAILURE ANALYSIS

GEAR FAILURE MECHANISM (WEAR)

 SCORING AND WELDING:
• Is the rapid removal of material from the tooth surface.
• Sliding forces tear the metal from the surface producing a
minute cavity in one surface and a projection on the other.
• Occurs in localized areas on the tooth where high contact
pressure exists.
• The tip or root where sliding velocities, and hence contact
temperatures are high.
• Direct causes of scoring are high contact temperature and
pressure and marginal lubrication.
 GEAR BOX FAILURE ANALYSIS

GEAR FAILURE MECHANISM (WEAR)

SCORING AND WELDING

 GEAR BOX FAILURE ANALYSIS

GEAR FAILURE MECHANISM (PLASTIC FLOW)

• The cold working of the tooth surfaces, caused by high
contact stresses and the rolling & sliding action of the mesh.
• Surface deformation resulting from the yielding of the surface
and subsurface material.
• Is usually associated with the softer gear materials.
 GEAR BOX FAILURE ANALYSIS

GEAR FAILURE MECHANISM (BREAKAGE)

• The ultimate type of gear failure.
• Bending loads on gear teeth usually cause the highest
stresses at the root.
• Gear tooth is a cantilever plate with tensile stresses on the
contact side of the tooth and compressive stresses on the
opposite side.
• The tensile stresses at the critical location exceed the
endurance strength of the tooth material.
• Fatigue cracks will eventually develop and with continued
operation will break away from the rim material.
• This type failure is prevented by protecting the gearing from
high impact or transient loadings.
 GEAR BOX FAILURE ANALYSIS

ANTI-FRICTION BEARING FAILURE

MECHANISM

 CORROSION
 CONTAMINATION OF THE LUBRICANT
 OVERHEATING
 INADEQUATE INTERNAL CLEARANCE
 UNEXPECTED VIBRATORY LOADS
 MISALIGNMENT
 INADEQUATE LUBRICATION
 GEAR BOX FAILURE ANALYSIS

ANTI-FRICTION BEARING FAILURE

MECHANISM (CORROSION)

 CORROSION: A bearing can be failed before it is placed

into service, if it is improperly stored prior to installation.
• Damage due to corrosion manifests itself by a surface that
appears to be stained.
• Under magnification, this area contains a series of pits
which serve as a nucleus for a spall which leads to a
complete failure shortly.
 GEAR BOX FAILURE ANALYSIS

ANTI-FRICTION BEARING FAILURE

MECHANISM (CORROSION)

Corrosion leading to Spalling

 GEAR BOX FAILURE ANALYSIS

ANTI-FRICTION BEARING FAILURE

MECHANISM (CONTAMINANTS )
• Solid contaminants in the lubricant can produce a denting
of the rollers, balls, or races of a bearing. Dents become a
stress raiser from which a pit will be formed.
• The contaminant in the oil may be very fine and the oil will
have the appearance of silver paint.
• Bearing with fine contaminants will experience a lapping
severe enough to increase the bearing clearance by .010 to
.020”.
• Water accelerated fatigue takes place when water
concentration exceeds 100 ppm which can reduce bearing
life from 30 to 80%.
• 14 % of bearings fail due to contaminants.
 GEAR BOX FAILURE ANALYSIS

ANTI-FRICTION BEARING FAILURE

MECHANISM (OVERHEATING AND
INTERNAL CLEARANCES)
• The overheating can be caused by insufficient internal
clearance.
• Due to insufficient clearance metal to metal contact rises
frictional heat.
• If the thermal expansion of the bearing elements is greater
than the internal clearances and the bearings will load
themselves.
• The heat will become intense enough to weld the rollers to
the races.
 GEAR BOX FAILURE ANALYSIS

ANTI-FRICTION BEARING FAILURE

MECHANISM (OVERHEATING AND
INTERNAL CLEARANCES)

WELDING OF ROLLERS
 GEAR BOX FAILURE ANALYSIS

ANTI-FRICTION BEARING FAILURE

MECHANISM (VIBRATORY LOADS AND
MISALIGNMENT)
• 34 % of bearings fail due to fatigue associated with vibration
and misalignment.
• L10 life of bearing is reduced to half, on 20% increase in
load due to vibration and misalignment.
• Outer race faults are most commonly associated with high
vibration.
• Cocked bearing, bend shaft, and vibration from other
machines may also be the probable cause.
• Proper tools and precision maintenance/installation
techniques are necessary to avoid these failures.
 GEAR BOX FAILURE ANALYSIS

ANTI-FRICTION BEARING FAILURE

MECHANISM (OVER/UNDER
LUBRICATION)
• 36 % of bearings fail due to over/under lubrication.
• Bearing cap should never be filled more than two third.
• Lubrication related issues generate high frequency
ultrasonic sound.
• Special purpose acoustic techniques are used for early fault
detection.
• DB level is measured while bearing greasing and noted for
future reference.
 GEAR BOX FAILURE ANALYSIS

ANTI-FRICTION BEARING FAILURE

MECHANISM (Condition Monitoring
Techniques)

• Vibration Analysis.

• Acoustic Emission.

• Oil analysis.

• Wear Particle Analysis.

• Infrared Analysis.
 GEAR BOX FAILURE ANALYSIS

CONTACT OIL SEALS FAILURE

• The oil seal functions by either preventing oil from leaking
from an enclosed drive or by preventing the ingress of dirt.

• Damage to seal in handling or mounting.

• Hardening and cracking due to heat or chemical attack.

• Improperly prepared or damaged shaft journal.

• The shelf life of a seal can be considered indefinite if stored

in accordance with the manufacturer’ recommendation.
 GEAR BOX FAILURE ANALYSIS

CONTACT OIL SEALS FAILURE

• CUT SEAL LIP: it is very possible to cut or nick the seal lip
as it is slipped over a burr, keyway or spline.

• DAMAGED OR DISTORTED SEAL CASE: A distorted seal

case can be caused by a seal outside diameter too large for

the bore.

 SCORED OUTSIDE DIAMETER OF SEAL CAGE. A leak

around the O.D is usually caused from a burr or other
machining imperfection in the housing bore that receives
the seal.
 GEAR BOX FAILURE ANALYSIS

CONTACT OIL SEALS FAILURE

(HARDENING & CRACKING)
• Elastomers harden, crack and chip at the lip-shaft interface
due to excessive heat or exposure to chemicals.
• This results in heat cracking, chipping of seal lip & blisters
on seal lips.
 GEAR BOX FAILURE ANALYSIS

CONTACT OIL SEALS FAILURE

(EXCESSIVE LIP/JOURNAL WEAR)
• The width of the wear band of a normally wearing seal is
.010 - .030“
• If width is wide on one side and narrow on other it can fail
either due to inadequate wear band or due to excessive
contact resulting in overheating.
• Seal or shaft misalignment is the cause. Probably shaft is
misaligned in bore.
• If the wear path is wider than .030" or deeper than what
you can feel with your fingernail, leakage may be
encountered.
• The causes of this condition can be abrasive conditions,
eccentricity between seal and shaft or cocked seal.
 GEAR BOX FAILURE ANALYSIS

CONTACT OIL SEALS FAILURE

(EXCESSIVE LIP/JOURNAL WEAR)

 Either the should be resurfaced or the seal should be relocated

along the shaft in order to provide a new shaft surface.
 GEAR BOX FAILURE ANALYSIS

Shaft failure is very less encountered


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