How to judge the wear degree of worm gear of WPKA175-15-A reducer

Judging the degree of wear of the worm gear of the WPKA175-15-A reducer requires comprehensive visual inspection, operating status analysis and precise measurement. The specific methods are as follows:

1. Appearance inspection

1. ‌Tooth surface wear characteristics‌

• If the tooth surface of the worm gear (copper alloy) has scratches, grooves or metal debris accumulation along the sliding direction, the surface roughness will increase significantly, indicating the existence of uniform wear.

• If the tooth surface of the worm (steel) is partially polished or dented, material transfer may occur due to sliding friction.

• Gluing damage is manifested as metal adhesion, tearing or melted plaques on the tooth surface, which are dark brown in color. In severe cases, traces of 'bite welding' can be seen.

• ‌Pitting and Cracks‌

• Scattered pits (pitting corrosion) or fine cracks in the tooth root appear on the tooth surface, which require observation with a magnifying glass, indicating the risk of fatigue wear.

2. Operating status monitoring

1. ‌Abnormal noise and vibration‌

• In the early stage of wear, the noise changes from 'smooth sound' to 'rustling sound', and 'piercing scream' or periodic impact sound occurs during gluing.

• If the vibration amplitude exceeds 0.15mm/s (detected by a vibration meter) or the coin is unstable, it indicates abnormal meshing.

• ‌Temperature and efficiency changes‌

• The temperature of the bearing seat exceeds 65°C or the oil temperature rises suddenly (>80°C), which may be caused by increased friction.

• Transmission efficiency below 60% (input/output power comparison) indicates tooth surface wear or deformation.

3. Precision measurement and quantitative evaluation

1. ‌Tooth thickness and gap measurement‌

• Use a tooth thickness caliper to measure the tooth thickness of the worm gear/worm. If the wear exceeds 10% of the original tooth thickness (such as 5mm worn to <4.5mm), it needs to be replaced.

• Use a feeler gauge to detect the meshing backlash. If it exceeds the design value by 50% (such as 0.2mm to >0.3mm), it indicates serious wear.

• ‌Professional equipment testing‌

• The gear measurement center scans the tooth profile deviation, CALYPSO software analyzes the single tooth wear curve, and PiWeb generates an overall report.

• If the iron content in the oil sample is >100ppm (spectrometer), it indicates gear or bearing wear.

4. Repair and replacement decisions

• ‌Mild wear‌ : Honing to repair the tooth surface and adjust the meshing clearance.

• ‌Moderate or above wear‌ : parts need to be replaced when the tooth thickness is thinned by more than 15%, the bonding area is >30% or the tooth is broken‌.

Multi-dimensional assessment can accurately determine the degree of wear and avoid transmission failure due to delayed maintenance.