What are the solutions to uneven wear caused by manufacturing defects in the TY140-35.5-7.5KW reducer gear?

In view of the uneven wear caused by the gear manufacturing defects of the TY140-35.5-7.5KW reducer (tooth shape/tooth direction deviation, excessive surface roughness, uneven tooth thickness, uneven material heat treatment, processing holes/burrs, etc.), combined with the working condition characteristics of this model of equipment with a rated power of 7.5KW and a transmission ratio of 35.5, the 'Emergency Loss Control - Repair and Rectification - Replacement and Adaptation - Long-term Prevention' In accordance with the principle, a feasible solution has been formulated, taking into account the installation, lubrication, and operating parameter matching requirements of this type of equipment, as follows:

1. On-site emergency loss control to curb increased wear : For working conditions where manufacturing defects are minor, wear does not reach the scrap standard and the equipment cannot be shut down immediately, the 7.5KW light and medium load operating characteristics are adapted to control the actual load at 60%-70% of the rated load to avoid excessive local stress on the tooth surface caused by unbalanced load; replace L-CKD220 extreme pressure anti-wear gear oil, replenish the oil level to the center line of the oil mark, and control the oil contamination level at NAS8 through the oil filter. Within the level, shorten the oil change cycle to 3 months and test the oil iron content every 15 days; recalibrate the coaxiality of the input/output shaft, radial deviation ≤ 0.05mm, end face deviation ≤ 0.02mm, eliminate the superposition effect of installation deviation and manufacturing defects, and check the bearing clearance. If it exceeds the standard, replace it in time to avoid gear meshing deflection; monitor the noise of the reducer during no-load operation, and immediately reduce the load if abnormal noise occurs to prevent local wear from rapidly developing into chipping or broken teeth.

2. Precise repair and rectification to restore gear accuracy : For repairable manufacturing defects (slight tooth shape/tooth direction deviation, excessive surface roughness, uneven local tooth thickness, and no damage or peeling of the gear base), repairs are carried out according to the design accuracy of the gear of this model (GB/T10095-2008 Level 7); tooth shape/ The tooth direction deviation is corrected by fine grinding with a CNC gear grinding machine to ensure that the tooth surface contact spots are ≥ 60% in the tooth height direction and ≥ 70% in the tooth width direction. If there is no tooth grinding, use tooth shape grinding paste to manually grind the stress concentration area; if the surface roughness exceeds the standard (Ra>1.6μm), fine honing/ Polishing treatment controls the tooth surface roughness to Ra0.8-Ra1.6μm to eliminate microscopic burrs and knife marks; 20CrMnTi is used for local uneven tooth thickness (deviation ≤0.1mm) The thin parts of the wear-resistant welding wire are cold cladded to avoid welding deformation, and subsequent finishing turning and gear grinding restore the standard tooth thickness; uneven heat treatment (tooth surface hardness difference ≥HRC5, hardened layer depth <1.5mm) uses secondary local induction quenching, and the supplementary quenching hardness is uneven In the sufficient area, control the tooth surface hardness to HRC58-62. After quenching, perform low-temperature tempering to eliminate internal stress and prevent tooth surface cracking. After repair, the gear meshing clearance needs to be detected to match the design requirements of this model (0.15-0.25mm).

3. Replace the adapting accessories and completely eliminate the source : For working conditions with serious manufacturing defects (tooth shape error ≥ 0.05mm, tooth direction deviation ≥ 0.03mm, large surface area processing defects, unqualified materials, or tooth surface peeling, potholes, tooth thickness reduction ≥ 10% of the design value), and the accuracy cannot be guaranteed after repair, purchase strictly according to the original design drawings of TY140-35.5-7.5KW/ Customized gear accessories, make it clear that the material is the original manufacturer's designated brand (20CrMnTi is preferred), and provide material test sheets, heat treatment reports, and accuracy test reports; complete acceptance after arrival, detect tooth shape/tooth direction deviation, tooth thickness, common normal length, use Rockwell hardness tester to detect tooth surface/tooth core hardness, magnetic particle inspection to check for blisters and cracks, unqualified parts are strictly prohibited to be installed; follow the principle of pair replacement, driving wheel/ If one of the driven wheels is severely worn, replace the gear pair at the same time to avoid mismatch in matching accuracy between the old and new gears and wear again. At the same time, check whether the gear shaft is deformed, and correct or replace the deformation simultaneously. Before installing the new gear, clean and remove anti-rust oil, apply assembly grease, and strictly ensure the meshing gap and contact spots. After installation, perform no-load running-in for 2-4 hours (the speed is 50% of the rated speed), and then gradually load it to the rated load. During the running-in period, monitor the tooth surface temperature ≤ 80°C and no abnormal noise, and confirm that the meshing is normal before putting it into operation.

4. Optimize supporting processes to improve anti-wear capabilities : For the working conditions of this type of equipment, auxiliary measures are used to make up for minor manufacturing defects and improve gear transmission stability; install a high-precision oil filter (filtration precision ≤ 10 μm) in the lubricating oil circuit to prevent abrasive particles from entering the tooth surface and aggravating wear; if conditions permit, install an oil temperature sensor to monitor the oil temperature in real time to avoid oil film rupture caused by excessive oil temperature; surface strengthening treatment (nitriding/nitriding/ Shot peening) to improve tooth surface hardness and wear resistance and extend service life; check the sealing system of the reducer and replace aging oil seals and gaskets to prevent external dust and moisture from entering the oil and causing abrasive wear. At the same time, ensure that the breathable plug is unobstructed to avoid oil leakage caused by excessive pressure in the box.