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Falk Gear Reducer Failure Analysis: 6 Steps to Follow

February 29, 2012 | Comments: 0 | Views: 217

Enhanced efficiency, improved safety, and enriched overall performance can result from Falk gearbox failure analysis, in addition to lowered costs and environmental effects. To best understand why a Falk gear reducer failed, it's best to follow the steps we've listed below.

1. Choose a Leader and Gather Your Team.

Start by identifying a team leader with exceptional communication and organization skills, as well as a strong appreciation of failure analysis. As an example, when exploring the reason behind surplus gear reducers' failure, your leader should be able to define how much time and money is available for analysis. This information will be folded into an investigation plan that explains what steps must be taken in the failure analysis, why these steps are important, and the ultimate goal of the failure analysis inquiry.

Failure analysis teams usually include metallurgists, tribologists, and failure analysts. Consider the gear analyst the root of the team; this one individual should have a strong understanding of tribology, stress analysis, gear design and manufacturing, metallurgy, and (clearly) why gears fail.

2. Collect Assets.

You need lots of data to understand why surplus gear reducers and other industrial parts fail. Of course, the first thing that must be done is turning off the failing part, and isolating it so that no crucial evidence is lost to the investigation. To totally comprehend why a Falk gear reducer or other part ground to a halt, analysts require this information:

a. Visual inspection data.

b. Information on Gear Backlash.

c. Contact patterns for gear teeth, with different load levels included. (This assumes the gears are still turning, but evidence suggests misalignment is present.)

d. Temperature, vibration, and sound facts.

e. Circumstantial data - load information, service history, manufacturer' suggestions, etc.

f. Radial movement and endplay of pertinent shafts.

3. Remove the Gearbox.

If you don't have enough on-site space to take apart the gearbox, you may need to move it to the closest gear building plant. Keep in mind that it's not unusual for a Falk gearbox or other component to require a couple of overhead cranes for disassembly - in other words, these parts are quite large. Take your time. Notice the condition of seals, shafts, and fasteners before disassembly. Before you clean out gear housing check for clues of overheating, corrosion, lube leaks, and overheating. Rushing this disassembly process will only cause you to lose important information.

4. Disassembling the Gearbox.

Next, it's time to take apart the Falk gearbox or other system. Again, move slowly and consider yourself a Sherlock Holmes-ian analyst. Soak up and record as much data as possible; avoid leaping to conclusions. Take photographs and copious notes. One the part is disassembled, remember to look in the bottom of the Falk gearbox - it's not unusual for broken gear teeth to fall here.

5. Figuring out Why Failure Occurred.

Given the complexity of a modern Falk gearbox, it's impossible to fully explain why these parts fail, at least in an article of this length. Entire degrees are needed to comprehend gearbox failure. To give a general overview of this process, however, the failure analyst utilizes the information mentioned earlier in addition to gear geometry data and the results of other tests to decipher the cause of gearbox failure.

6. Convey Discoveries.

Lastly, the team will compile a thorough report to explain their conclusions.

Saving money in business is a common trend these days, and the industrial industry is no different. Knowing about things such as falk gearbox repairs can help cut costs on new equipment. Mar-Dustrial has provided industrial power transmission products and repair since 1947 and offers tips on their website

Source: EzineArticles
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