How will the wear of the CWU250-50-IF worm gear reducer change under different operating conditions?

There are significant differences in the wear of the CWU250-50-IF worm gear reducer under different operating conditions, which are mainly affected by factors such as load, environment, lubrication conditions, and operating time. The following is an analysis of wear changes based on typical working conditions:

1. Wear characteristics under high load conditions

When the reducer operates at conditions close to or exceeding the rated torque for a long period of time, the worm gear pair will bear greater contact stress, leading to accelerated wear.

• ‌Tooth surface gluing and pitting‌ : High load causes the oil film on the tooth surface to rupture, and direct metal contact generates local high temperatures, causing worm gear tooth surface gluing (adhesive wear), followed by pitting and spalling.

• ‌Transmission efficiency decreases‌ : Increased friction causes efficiency to drop from normal 70%-90% to below 50%, energy loss increases, and temperature rise intensifies.

• ‌It is recommended that the control load does not exceed 80%-100% of the rated value ‌ to avoid continuous overload operation.

2. Wear mechanism in dusty and humid environments

In harsh environments such as mining and metallurgy, external pollutants can significantly increase wear and tear.

• ‌Abrasive wear‌ : Dust invades the box and mixes with lubricating oil to form 'abrasive', causing scratches and pits between the tooth surfaces, which is a typical three-body wear.

• ‌Seal failure chain reaction‌ : Dust wears the oil seal lip, causing lubricating oil to leak, further aggravating poor lubrication.

• ‌Hot and humid environment risks‌ : Water enters the oil and causes emulsification, reducing lubrication performance and corroding the metal surface. It is recommended to regularly check the water content of the oil (>0.1% requires oil change).

3. Wear caused by improper lubrication management

Lubrication is a key factor in determining wear rate, and improper operation can cause systemic damage.

• ‌Oil Selection Error‌ : Use ordinary gear oil instead of extreme pressure worm oil (such as N220/N320). Due to the lack of sulfur and phosphorus additives, an effective protective film cannot be formed, resulting in early wear.

• ‌The oil change interval is too long‌ : If the running-in oil is not replaced for the first 100 hours of operation, the remaining iron filings will accelerate secondary wear; subsequent failure to change the oil after the expiration date will cause oxidation of the oil, accumulation of impurities, and an increase in the wear rate by more than 50%.

• ‌Insufficient oil quantity or offset oil injection‌ : In the forced lubrication system, if the nozzle deviates from the meshing area by ≤2mm, it may cause insufficient lubrication and cause local dry friction.