Race C2

CURSO: MONITOREO DE CONDICIÓN Y ANALISIS DE FALLAS Semester: VI

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WORKSHOP GUIDE - No. 05

ACTIVITY: VISUAL INSPECTION OF GEARS

PROFESSOR: Darío Frías WORKSHOP:

M2 PERIOD: 2018-2 GROUPS A B C D

Result:

Criterio de Desempeño :

Activity: Visual Inspection of Gears

 Race C2
CURSO: MONITOREO DE CONDICIÓN Y ANALISIS DE FALLAS Semester: VI
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SPECIFIC COMPETENCIES:

Correctly apply the procedure to conduct a visual inspection of the gears using
a gear reusability guide
Correctly identify different types of abnormal wear in gears
Prepare a technical report with the results of the visual inspection.

ACTIVITY 01 Nomenclature and Types of Gears

Using the gear reusability manual, you must create a summary of the types of gears and
its corresponding nomenclature.

No. IMAGE NAME AND SPECIFICATION

Toothed wheels
1 Straight gears have parallel axes. The load is applied to a single
tooth. The load is applied to 1/3 of the adjacent tooth.

Image (1)

Helical gears
Helical gears have parallel axes or perpendicular axes.
2
The helical gears are silent. Multiple teeth carry the
load.

Image (2)

Straight bevel gears

Straight bevel gears have angled shafts or perpendicular shafts.
3
Approximately 1 and 1/3 teeth carry the load. Some thrust occurs.
final.

Image (3)

Helical gear
The hypoid pinions or the spiral gear shafts are
perpendicular to each other. The teeth of the gear are curved to
4 provide more contact area between the coupling teeth. The
design creates a silent operation with more
Slide the tooth contact, and complete the push. Two or more teeth.
they carry the load.
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COURSE: CONDITION MONITORING AND FAILURE ANALYSIS Semester: VI
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Image (4)

Screw gear wheels

They are a particular case within the helical gears, in which the
A pinion is a screw with a helical thread that has one or more
entries.
5
[Link]
I need

Image (5)
Table No. 1
NOMENCLATURE:

Nomenclature of Gears
item description
1 End
2 tip
3 land of the point
4 edge
5 face of the tooth
6 Highest single tooth contact point (HPSTC)
7 Pitch Line
8 Lowest point of contact of a single tooth (LPSTC)
9 Fillet
10 Root
11 Active profile start.
12 crown
13 profile
14 Pitch diameter of the gear.
15 push face
Table No. 2

Imagen (6)
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CURSO: MONITOREO DE CONDICIÓN Y ANALISIS DE FALLAS Semester: VI
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ACTIVITY 02 Specifications of the Heat Treatment

Using the gear reusability manual, you should create a summary table with the specifications.
techniques related to the heat treatments performed on gears

THERMAL TREATMENTS

Nitriding Carburization
Nitriding provides a thin hardened layer. Carburized gears are typically used in.
deep, generally from 0.13 mm (0.005 in.) to 0.3 applications with the highest loads. The gears
mm (0.01 inches). The nitride gears, which are carburized, are normally used in the drives.
they require greater dimensional precision, final loads. The layer depths can vary from
with lighter loads. 0.5 mm (0.02 in) to 2.0 mm (0.08 in).

Image (7) Image (8)

Table No. 3
ACTIVITY 03 Operational Characteristics of Gears
Using the gear reusability manual, you must prepare a summary table with the main points.
operational conditions and/or characteristics of the gears

METHODS TO MINIMIZE GEAR FAILURES

Trains become contaminated very easily. When assembling, the procedure must be
1 clean since this minimizes the possibility of contamination.
The oil levels must be appropriate; only the lubricants recommended by the manufacturer should be used.
2
caterpillar to minimize waste generated internally due to wear.
3 Replace the dirty air filters as this minimizes air pollution.
Se debe de programar un servicio de análisis de aceite ya que esto puede ayudarnos a determinar la causa
a possible failure, an oil analysis can help us prevent potential future failures. It should be
4
keep an accurate record of machine hours. The information will be used during an analysis of
oil to be able to generate a more accurate diagnosis
The specified filters must be used and changed according to their recommended interval if gear oil.
5
goes through a filtering system.
Change the drive train oils at the recommended intervals, the intervals can be found
6
in the machine's service manual.
Ensure that the gears are free of rust and debris during construction, examine them.
7
gears to check for damage due to handling.
The gears must be handled with care; they should also be stored with caution.
8
store properly during reconstruction. The gears can be easily chipped.
9 Record the usage hours of the component
Table No. 4
 Race C2
CURSO: MONITOREO DE CONDICIÓN Y ANALISIS DE FALLAS Semester: VI
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ACTIVITY 04 Visual Inspection Procedure

Using the gear reusability manual, you must create a summary of what is requested:
Importance of conducting a good visual inspection

It is important because through visual inspection, the original cause of the problem can be determined.
It is a more meticulous procedure which makes it more reliable, allowing it to be carried out this way.
an action to prevent the failure from happening again
The probability of discovering the main cause is much higher.

List of necessary tools for visual inspection

No. TOOL IMAGEN

1 Flashlight or light source

Image (9)

2 Magnifying glass for eyes

Image (10)

Tape measure or another device

3
of measurement

Image (11)

4 Inspection mirror

Image (12)
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CURSO: MONITOREO DE CONDICIÓN Y ANALISIS DE FALLAS Semester: VI
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Image (13)

Inspection meters of
5
welding size

Image (14)
Table No. 5
Describe in detail the procedure for conducting a visual inspection on gears.

1. Clean all the gears thoroughly before inspecting them. Refer to 'Prepare the area for
inspection

2. Inspect the entire surface of the gear for the following damages:

Pitting
Spalling
Cracking
Any other damage

It is possible that only one tooth is damaged.

3. Carefully inspect the gear hole with a bright light. The holes of the
Bearings for planetary gears can be sensitive to high loads and speeds. The inspection
Damage care is critical.

Rim of gear
Spline
Bearing surface

4. The bearing holes may have minimal wear or only damage.

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CURSO: MONITOREO DE CONDICIÓN Y ANALISIS DE FALLAS Semester: VI
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5. Use Table No. 6 or Image (15) to ensure that the gear is inspected for detection.
every possible harm.

Table translated into Spanish

LIST FOR INSPECTING GEARS
Item Yes No
Normal wear

White scale cover

Use from peak hour

Abnormal wear

Cream

Sting

Initial

Corrosion

Destructive

Detachment

Sting or disintegration

Tanteo

Crush case
Corrosion or pitting
corrosive
Abrasive wear

Mellas

You shout

Splintered

Unequal contact

Damage from foreign objects

Waviness or lipping

Drills in gears
Perorations in gears
planetariums
Gears with bearing Image (15)
replaceable
Table No. 6
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CURSO: MONITOREO DE CONDICIÓN Y ANALISIS DE FALLAS Semester: VI
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ACTIVITY 05 Machining Identification

Using the gear reusability manual, create a summary table explaining the following:
Clearly define the concept of machining and attach reference images of the types of machining.
CONCEPT OF MACHINING

Set of processes (cutting, marking, stamping, drilling, etc.) carried out on a metal piece
to give it a final shape and size.

TYPES OF MACHINING

Machining without chip removal

Image (16)

Machining by chip removal

Image (17)
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Turning

Image (18)

Milling

Image (19)
Table No. 7
Clearly define the concept of rough machining and attach reference images.

Concept of Rough Machining

The teeth of the gear are often machined using a bench process. If a
The gear has undergone a countertop process, it is easy to notice the machining marks.
raw on the surfaces of the teeth and the burrs on the edges of the teeth.
The marks on the countertop (1) are visible in
the face of the tooth in the gear in the
image. The marks and burrs of
rough machining leftovers from the
countertop process will be eliminated during
the final machining process.

Image (20)
Image (21)
Table No. 8
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CURSO: MONITOREO DE CONDICIÓN Y ANALISIS DE FALLAS Semester: VI
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Clearly define the concept of finish machining and attach reference images.

Concept of Finish Machining

A machining process is used after the gear teeth have been cut with the
Countertop process. This process is called shaving. Illustration 36 shows the appearance of a new one.
Gear that has undergone the shaving process. This gear is ready for heat treatment.

The image shows new equipment that has not gone through the heat treatment process. The marks
The shaving marks (2) shown in Image (22) will be visible after many hours of use. These
marks are placed on the face of the tooth at a slight angle.
The root fillet area is not a contact surface, so the root fillet area does not require the
final machining process. The marks on the plate (1) will be left on the root fillet. This gear is
ready for heat treatment.

Image (22)
Table No. 9

ACTIVITY 06 Identification of Normal Wear

Using the gear reusability manual, create a summary table explaining the following:
Clearly define the concept of normal wear and attach reference images.

NORMAL WEAR
This section will describe the types of normal wear patterns that a gear may develop.
Normal gears consist of a flaked white layer and high hour wear.
Generally, gears that show only normal wear can be reused.

In the image (23) we can notice that in the

The gear shows normal wear and very
You can also notice the morning.
still.

Image (23)
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CURSO: MONITOREO DE CONDICIÓN Y ANALISIS DE FALLAS Semester: VI
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Image (24)
We can see that the edge has a well-defined contact line.
This indicates that it is also a Normal Wear.

Image (25)
This gear shows a wear pattern.
From the teeth, the wear pattern of the teeth seems normal.

Clearly define the concept of White layers flaking and attach reference images.

White layers flaking (White Layer of

Scabbing is the hardening with nitride
developing thin and brittle skin
that could be released during the
normal operation.
Image (26)
This image shows the peeling of the white layer.
The equipment can be reused
 Race C2
CURSO: MONITOREO DE CONDICIÓN Y ANALISIS DE FALLAS Semester: VI
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Image (27)
In this image, point to the white scaled layer, this is a
normal result of heat treatment operations.
The equipment can be reused.

Table No. 10
Clearly define the concept of wear from high hours and attach reference images.

Image (28)
Wear from high hours This image shows a smooth surface and it must be
hours) is a normal wear where the approximately two thirds or more of the length of the tooth
of the gear, and also that the wear must be in the
gear has already had high hours of
center of the tooth profile.
functioning.

Image (29)
The machining marks are still shown with arrows.

Table N°11
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Conduct a visual inspection of a gear and look for evidence of normal wear. Attach photos as
evidence.

CONDITION PHOTOGRAPHIC EVIDENCE CAUSAS QUE LO ORIGINAN

Presents a: This gear presents a
White layers flaking decay in the teeth
Wear from high hours this may be due to the
part to state functioning at
long working hours
causing wear in
the teeth the enlargement must
to be replaced since
to continue working like this
it can cause a break
in the teeth and in the long run one
internal failure.

Image (30)
Table No. 12

ACTIVITY 07 Identification of Abnormal Wear

Using the gear reusability manual, create a summary table explaining the following:
Clearly define the concept of abnormal wear.

The reusability manual indicates that abnormal wear is often due to

From the operational conditions, the damages suffered can be corrosion, abrasion, adhesion,
plastic deformation in the component. If the necessary measures are not taken and it is allowed to continue
Wear
operating under those conditions, it is most likely that one of the gear's teeth will
abnormal.
break causing greater damage. The cause not only influences the operational environment but also
also the poor procedure in the adjustment of the components during assembly can be a
cause of the component not reaching the estimated lifespan.

Image (31)
Table No. 13
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CURSO: MONITOREO DE CONDICIÓN Y ANALISIS DE FALLAS Semester: VI
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Defina claramente el concepto de frosting, pitting, destructive pitting, spalling, pitting and spalling, corrosión
and corrosive pitting, scoring, case crushing, abrasive wear, nicks, cracks, chipping, uneven contact, damage
for foreign object, ripping, lipping and I attached reference images of each type of wear
abnormal.
Frosting
Frosting occurs when the teeth of the gears that are engaging make contact.
metal with metal. Metallic contact generally results from an inadequate oil film between the
surfaces of the coupling gear teeth. Frosting is not harmful to a gear if it has not been
the pitting has started. The frosting is not harmful to a gear if the profile has not changed. The frosting appears
like a cloudy gray area on the surface of the gear contact. The gears that seem to show signs of
frost can be used again if the gear is free of other types of damage. The Frostining can be the
result of the following problems:
High operating temperatures that cause the lubrication viscosity to thin.
Heavy loads
Incorrect lubrication
Incorrect part

Image (32)
We can observe a Frostining signal; this is caused because the gear had a poor film of
this caused a metal-on-metal collision and the result we get after this effect is a
frosting.

Table No. 14

Pitting
The cavity is the development of small holes on the surface of a tooth. The cavity is caused by the
stress caused by fatigue from contact on the surface of a gear tooth. Holes develop
mainly at the bottom of a gear tooth near the LPSTC of the driving gear.

Image (33)
Table No. 15
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Destructive Pitting
Destructive bites usually occur after the theft period for up to 500 hours. The bites
Destructive features will generally be found in most gear teeth. The deep pits.
They will progress towards decay and a fracture if the causes of the destructive bites are not corrected.

Image (34)
Table No. 16

Spalling
It is a type of fatigue failure that occurs beneath the surface. The detachment is the result of a small
crack that has passed through the face of the gear and under the hardened surface case. The pitting
Destructive bites or crushing of the box can cause decomposition. Destructive bites are usually
the starting point for the disintegration

Image (35)
Table No. 17

Pitting and Spalling

A combination of sting and peeling occurs during the transition process between stings and
detachment. The wear is due to the sliding and rolling action between the tooth. A team with evidence of
stings and detachment should not be used again. The detachment can progress rapidly in a
fracture

Image (36)
Table No. 18
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CURSO: MONITOREO DE CONDICIÓN Y ANALISIS DE FALLAS Semester: VI
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Corrosion and Corrosive Pitting

Corrosion can be caused by an electrolyte that has entered the lubrication system. The electrolyte most
Water is common. Corrosion can cause pitting.
Correct the cause of corrosion before corrosive pitting occurs. If an electrolyte enters the train
motor, the electrolyte can neutralize the additive package in the oil.

Image (37)
Table No. 19
Scoring
Scoring can result from metal-to-metal contact. Scoring can cause vertical scratches that
They are perpendicular to the slope line. The scoring starts above the field.
Line and below the tone line. The punctuation develops when a sliding action occurs between
two coupling teeth.

Image (38)
Table No. 20

Case Crushing
It is a fault in the hardened surface of a gear box. The case is the surface and the core is the center.
The case of a tooth is much harder than the core of a tooth. The crushing of the box seems similar to a
object that has been pulverized. When a crushing of the box occurs, the softer core may remain
exposed.

Image (39)
Table No. 21
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CURSO: MONITOREO DE CONDICIÓN Y ANALISIS DE FALLAS Semester: VI
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Abrasive Wear
Abrasive wear is caused by small contaminants in the lubrication system, such as the following:
Soil
Arena
Metal
The small particles will eventually wear down the surface of the teeth. The small particles can
even alter the profile of a gear. The abrasive material can travel along the gears in the train of
transmission and the abrasive material can also damage other gears.

Image (40)
Table No. 22

Nicks
Notches generally occur when equipment is not handled properly before heat treatment.
Since most of them will occur before the heat treatment, a gear with a notch may
reuse.

Image (41)
Table No. 23

Cracks
It is difficult to visually distinguish a difference between a scratch and a crack. Inspect the gear for
cracks with any of the methods to inspect the cracks. Refer to
"Metallurgy" to obtain more information about the equipment and procedures needed that are required for
determine if there are cracks present.

Image (42)
Table No. 24
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CURSO: MONITOREO DE CONDICIÓN Y ANALISIS DE FALLAS Semester: VI
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Chipping
The wear pattern must be checked on gears with chipping. Misalignment will cause the load to increase.
tooth edge. Misalignment can cause chipping.
Multiple teeth usually chip under a misaligned load.

Image (43)
Table No. 25
Uneven Contact
The normal contact pattern will lead to a maximum service life if the application, operation, and procedures of
Maintenance is adequate. The contact at the tip of the tooth can cause a break.
Contact at the tip of the tooth can cause marks, bites, and breaks. The contact that concentrates on the
root can lead to puncturing and stinging. The contact that is concentrated at the tip can lead to spots.
bites and breaks.

Image (44)
Table No. 26
Damage for Foreign Object
Strange objects are items that are not allowed on the transmission train. A common strange object...
It will come from the transmission train. In difficult conditions, gear teeth.
And the roller bearings can break. Foreign objects can damage other components in the train.
of transmission. Broken teeth from other gears and defective bearing parts are
The two most common types of foreign objects.

Image (45)
Table No. 27
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Ripping
The gear has waviness damage shown between the lines. This type of damage would be more common in
highly loaded gear teeth.

Image (46)
Table No. 28
Lipping
The gear has wavy damage shown between the lines. This type of damage would be more common in
highly loaded gear teeth.

Image (47)
Table No. 29

Clearly define the concept of gear bores and indicate what should be inspected, attach images of
reference

GEAR BORES
Gear perforations in transmission trains are susceptible to damage. If the gear is to be reused, the
The hole must have no wear or damage.
• A good light source is required to fully inspect the inner diameter of a gear.
• Refer to 'Prepare the area for inspection' to clean the gear hole.
• If the gear hole has stains that cannot be removed with reconditioning of the
surface 8T-7765
• Pad and solvent, do not reuse the gear
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CURSO: MONITOREO DE CONDICIÓN Y ANALISIS DE FALLAS Semester: VI
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Image (48)
Table No. 30

Clearly define the concept of splines and indicate what should be inspected, attach reference images.
SPLINES
Inspection mode:
The grooves should be checked for wear with a sealant.
The selection of the seal must be kept perpendicular to the groove.
If the selection is stopped due to any of the wear steps, do not reuse the gear.
Visually check for any other damage in the slot before using the gear again.
Refer to the Inspection of Striations section within Reuse and Recovery Guide, SEBF8443 for
appropriate inspection and measurement procedures.

Image (49)
Table No. 31

Clearly define the concept of thrust faces and indicate what should be inspected, attach images of.
reference
THRUST FACES
The thrust face of a planetary gear, sun gear, or side gear must be free of stains or
heat controls. Heat controls are shallow cracks that interrupt the lubrication film.
The heat controls can release material from the thrust bearing. Gears with slight damage to the
push faces can be used again.
Inspection :
Inspect the gear for cracks using any of the methods for inspecting cracks.
The full push face does not meet reuse standards.
Also take into account the discoloration
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CURSO: MONITOREO DE CONDICIÓN Y ANALISIS DE FALLAS Semester: VI
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Image (50)
Table No. 32
Perform a visual inspection of a gear and look for evidence of one or more types of abnormal wear.
As described above, please note that the inspection must include teeth, side faces, and hole of the
gear. Prepare a summary table with the results of the visual inspection. You can use the following
example as a model.
Take photographs and use the reusability guide to determine if the component can be reused.
Use the table shown as a reference to record the information.

ITEM CONDICIÓN PHOTOGRAPHIC EVIDENCE CAUSAS QUE LO ORIGINANCONCLUSION

High torque, over the

gear head
Corrosion
01 Contaminated lubricant with Do not reuse
pitting water

Electric shocks
Image (51)

This is due to the action

Pitting and
02 sliding and rolling among the Do not reuse
Spalling
gear teeth

Image (52)
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The contact of the end of

Uneven gear tooth can
03 Do not reuse
Contact to cause a break in the
tooth

Image (53)

About the load during the

Rippling lubrication.
04 Do not reuse
Corrosion Lubricant with H2O which
pitting hace presentar oxido en el
gear tooth

Image (54)

The misalignment can

to provoke one end of the
tooth take this
05 Chipping Do not reuse
will cause one end of the
tooth needed bigger
effort.

Image (55)

This is due to the bad movie

of oil which makes that
the metals clash from the
Frosting Can
06 gears.
Nicks to reuse
Nicks occur when one does not
they manage the treatment well
thermal.

Image (56)
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CURSO: MONITOREO DE CONDICIÓN Y ANALISIS DE FALLAS Semester: VI
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The destructive pitting occurs

when the gear goes from the
500 operational hours.
Scoring occurs when
Destructive
07 there is a sliding action of Do not reuse
Pitting
the coupling teeth it
cabbage causes those lines in the
tooth.

Image (57)

This happens during the process of

08 transition between stings and Do not reuse
detachment.

Image (58)

ACTIVITY 08 Recommendations to minimize gear failures

Use the gear reusability guide to summarize the main recommendations to keep in mind for
maximize the lifespan of the gears. Create a summary table.

OBSERVATIONS AND RECOMMENDATIONS OF THE ACTIVITY

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EVALUATION CRITERIA FOR ACTIVITIES

ASPECTS TO EVALUATE IN WORKSHOP POINTS SCORE

I SECURITY

1. Punctuality, Order, and Pollution Control 1

2. Use of PPEs 1

3. Safety Aspects during the activity (ATS) 2

II PROCEDURES, EQUIPMENT, TOOLS, AND MEASURING INSTRUMENTS

7. Compliance with procedures 4

8. Proper use of equipment and tools 4

9. Proper record of the visual inspection 4

IV COMMUNICATION SKILLS

10. Use appropriate technical terminology 3

11. Teamwork 1

TOTAL 20