In an ideal but sadly unrealistic world, mechanical components and various pieces of machinery would last forever. There would be no risks of friction or long-term wear-down concerns, and components like gears would simply never lose their high-level functionality for any reason.
At Butler Gear, we're here to help you deal with the simple reality that the above is not the case. Our custom gear manufacturing services, from gear shaping and grinding to broaching and many other mechanical processes, create the highest-quality gear products for you to use in replacing or upgrading older or worn-down gears. Why do gears, like any other piece of machinery, sometimes fail? Here are the common culprits and how you can look to ward off these concerns when installing new gears.
Gear Failure Basics and Concerns
Gear "failure" is a broad term that actually covers a few different specific issues, from gears that are unable to turn themselves to those that aren't connected properly with the underlying system, plus many others. In each of these cases, however, this is a big concern for you - not only because the gear won't be performing its stated purpose, but also because failing gears can damage or even destroy other vital machine components before long.
So why and how does gear failure happen? Our subsequent sections will dig into this question.
Design or Manufacturer Defects
In some cases, gears will not be designed or manufactured properly. This is a process that requires incredible amounts of precision, so even minor changes from the norm could create big issues down the line.
In many such situations, the gear in question may appear to work just fine initially. But whether it's a poor fit, a burr or any other issue, it will often show itself as a problem well before the gear would be expected to naturally wear down. This is why it's so important to work with a high-quality gear manufacturer like the team at Butler Gear.
While this is less common, any exposure to certain chemicals or sometimes even moisture alone could create corrosion and rust issues within your gears. This may make certain gears unable to turn if it's allowed to continue. If this is a potential risk, ensure your machinery is protected from any exposure to these substances.
Finally, gears that are used extremely often or in high-stress situations will suffer natural wear-and-tear concerns. The first of these are usually found in scuffs and chips, which might not be a huge issue individually but can become one when there are several of them throughout the gear. Over enough time, larger defects may arise and the gear could eventually fail. It's important to keep an eye out for natural wear-down signs - our team can help you with some of these and also advise you on when it's time to consider a replacement gear.
For more on the causes of gear failure, or to learn about any of our custom gear manufacturing services, speak to the staff at Butler Gear today.