How to improve the wear resistance of CWO140-25-I worm gear reducer

To improve the wear resistance of CWO140-25-I worm gear reducer, comprehensive optimization is required from multiple dimensions such as material, design, lubrication, installation and maintenance. The specific measures are as follows:

1. Materials and heat treatment strengthening

1. ‌Worm material selection‌

• High-strength alloy steel (such as 40Cr, 20CrMnTi) is used, and the surface hardness needs to reach HRC58-62 after carburization and quenching. The core part remains tough to withstand impact loads.

• The worm gear is preferred to use tin bronze (ZCuSn10Pb1) or aluminum bronze (ZCuAl10Fe3), and the hardness is controlled at HB80-120, which forms a 'hard-soft' pair with the worm to reduce adhesion wear.

• ‌Heat Treatment Process‌

• High-frequency induction quenching or carburizing quenching of worms ensures that the depth of the hardened layer is ≥0.8-1.2mm, and avoids early failure due to surface peeling.

• After casting, the worm gear needs to be aging treatment to eliminate internal stress and improve dimensional stability.

2. Design and manufacturing optimization

1. ‌Tooth surface parameter design‌

• A dual-guided worm (variable tooth thickness worm) is used. After wear, the meshing clearance can be restored through axial adjustment to extend the service life‌.

• The worm lead angle is controlled between 3°-27°, which balances efficiency and sliding speed to avoid excessive sliding speed aggravating wear.

• ‌Machine accuracy control‌

• The machining accuracy of worm gear and worm gear is not lower than level 7 of GB/T 10089, and the tooth surface roughness Ra≤1.6μm is ensured to ensure the meshing contact area≥70%.

• Strictly detect the tolerance of the worm helical line and the radial jump of the worm gear ring to avoid local stress concentration.

III. Lubrication management

1. ‌Lutrient Selection

• For ordinary working conditions, ISO VG 320 or 460 worm gear and worm special oil (including extreme pressure anti-wear additives).

• Use synthetic lubricating oil (such as PAO) for heavy load or high temperature operating conditions (>80℃), with a flash point of ≥240℃.

• ‌Luation method optimization‌

• When lubricating in the oil bath, the depth of the worm oil is 1-2 teeth heights, and the depth of the worm gear is 1/3 teeth width.

• The forced lubrication system must be equipped with an oil filter (accuracy ≤25μm) and a cooler, and the oil temperature should be controlled ≤70℃.

4. Installation and maintenance

1. ‌Precise Assembly‌

• Ensure that the perpendicularity of the worm and the axis of the worm gear is ≤0.02mm/100mm, and the center distance error is ≤±0.05mm to avoid excessive load wear.

• The coupling centering error is ≤0.03mm, reducing the impact of additional bending moment on the tooth surface.

• ‌Regular maintenance‌

• Check the seal status and oil cleanliness every 3-6 months to prevent contaminants from entering.

• The new machine will be replaced after running for 500 hours, and will be replaced every 2000-3000 hours or every year.

5. Environment and load control

1. ‌Avoid overloading operation‌

• The actual load shall not exceed 1.2 times the rated value, and the impact load must be reduced through buffering devices (such as elastic couplings).

• ‌Environmental adaptability

• High temperature environment (>80℃) requires enhanced cooling or switching to high-temperature lubricants; humid environments require regular inspection of anti-rust measures.