When repairing JS gear reducer gears after wear, it is necessary to choose an appropriate treatment plan based on the severity of the wear. It can usually be divided into three types: mild, moderate and severe wear:
1. Repair of mild wear and tear
If there are only slight scratches, burrs or surface roughness on the tooth surface, but it does not affect the overall meshing accuracy, the following methods can be used:
Grinding and polishing: Use oilstone, sandpaper or polishing machine to finely grind the tooth surface to remove burrs and tiny defects and restore the smoothness of the tooth surface.
Note: The pressure must be controlled during the grinding process to prevent excessive wear from causing changes in tooth profile. After repair, it is necessary to check the distribution of contact spots on the tooth surface.
2. Repair of moderate wear and tear
If the tooth surface is partially worn, peeled, or evenly worn but has not damaged the core structure of the gear, the following methods can be used to restore size and performance:
Overlay welding repair: First remove the oil stains and rust in the worn area, and then use welding rods that match the base material for layered surfacing welding. After welding, it is cooled slowly, and then the tooth shape is machined to ensure that the tooth side clearance meets the standard.
Thermal spraying/melting: Using flame spraying or plasma spraying technology, wear-resistant alloy powder (such as Ni60 or Co-Cr) is sprayed on the tooth surface to form a dense wear-resistant coating, which is then precision ground to the design size.
Gear tooth filling: If only a single or a few gear teeth are severely worn, a "filling block" matching the size of the original gear can be made, fixed with an interference fit or bolted connection, and a running-in test can be performed after repair.
3. Repair of severe wear and tear
When gear wear is very serious (for example, the tooth thickness is reduced by more than 10%, teeth are broken, or the hardened layer has been completely worn), the repair cost is often close to or exceeds the price of a new gear. At this time, the safest solution is:
Directly replace the new gear: select a new gear that completely matches the original gear parameters (module, pressure angle, number of teeth) for replacement.
Inspection of related components: When replacing gears, be sure to check the wear of shafts, bearings and other related components at the same time, and replace them together if necessary to ensure the stability of the overall transmission system.
