What are the causes of internal wear in the ZJY250-22.4 gear reducer

1、 Lubrication system failure (the highest proportion of core causes)

Incorrect selection of lubricating oil: Not using the appropriate N220/N320 extreme pressure anti-wear gear oil, and misusing ordinary mechanical oil can cause the oil film to easily rupture.

Abnormal oil level: If the oil level is too low to cover the meshing area, and if the oil level is too high, it can cause a sudden rise in oil temperature and oxidation and deterioration of the oil, all of which can damage the integrity of the oil film.

Oil aging pollution: Long term failure to change oil leads to the failure of additives, resulting in a significant decrease in lubrication performance when water and impurities are mixed in.

Lubrication channel blockage: The oil channel is blocked by oil sludge and metal debris, forming a local lubrication blind spot, and the tooth surface directly experiences dry friction.

2、 Load condition exceeds the design threshold

Long term overload operation: The actual load continues to exceed the rated torque, and the contact stress on the tooth surface far exceeds the design allowable range, accelerating the grinding and pitting of the tooth surface.

Frequent impact loads: The equipment frequently starts and stops, switches between forward and reverse directions, or the driven components get stuck and forcefully operate, resulting in instantaneous peak loads and causing tooth surface peeling.

Uneven force distribution under partial load: The misalignment of the shaft system causes the load to concentrate on a local tooth surface, and the wear rate of a single tooth surface far exceeds the normal area.

3、 Insufficient installation and debugging accuracy

Excessive coaxiality deviation: The misalignment error between the input shaft and output shaft, motor shaft and reducer shaft exceeds 0.05mm, causing meshing wear.

Improper tooth flank clearance: Insufficient clearance leads to poor heat dissipation in the meshing area and a significant increase in frictional resistance; Excessive clearance can cause impact and collision during operation, exacerbating tooth surface damage.

Failure of base fixation: Loose anchor bolts, tilted shell, continuous abnormal vibration during operation, amplified gear meshing impact.

4、 Impurities invade and form abrasive wear

External pollutant invasion: After the sealing components are aged and damaged, dust and water vapor from mining, cement and other working conditions enter the box and mix with lubricating oil to form abrasives.

Internal debris circulation wear: The metal and iron shavings generated by early wear were not filtered in time, and were repeatedly scraped by the oil on the meshing surface, forming tooth grooves and secondary wear.

Maintenance of residual impurities: Failure to clean the welding slag and burrs inside the box after disassembly and maintenance, resulting in direct scratches on the tooth surface during operation.

5、 Material and manufacturing process defects

The gear material does not meet the standard: the selected steel has excessive impurities, the tooth surface hardness does not meet the design requirements of HRC58-62, and the wear resistance is insufficient.

Shortcomings in heat treatment process: The depth of the carburized layer is less than 0.8mm, or there may be quenched soft spots or decarburization layers, resulting in a significant decrease in the fatigue resistance of the tooth surface.

Machining accuracy deviation: excessive tooth profile error, tooth surface roughness Ra>1.6 μ m, small contact area during meshing, local stress concentration leading to early wear.