Materials

<p style="text-align: justify;"><span data-preserver-spaces="true">A gearbox is a collection of mechanical components that deliver maximum power from an engine by managing a series of gear ratios that, in turn, operate a transmission. These components include:</span></p><ul style="text-align: justify;"><li style="list-style-type: disc;"><span data-preserver-spaces="true">Gear selector</span></li><li style="list-style-type: disc;"><span data-preserver-spaces="true">Fork</span></li><li style="list-style-type: disc;"><span data-preserver-spaces="true">Dogteeth</span></li><li style="list-style-type: disc;"><span data-preserver-spaces="true">Gear set</span></li></ul><p style="text-align: justify;"><span data-preserver-spaces="true">The gearbox,</span><span data-preserver-spaces="true">&nbsp;with its primary function of increasing or reducing speed, plays a crucial role in managing an engine's power output.</span><span data-preserver-spaces="true">&nbsp;This results in a proportional change in torque output, where an enclosed drive as a speed reducer (speed output is less than speed input) will increase torque&nbsp;</span><span data-preserver-spaces="true">output,</span><span data-preserver-spaces="true">&nbsp;and vice versa.</span></p><p style="text-align: justify;">&nbsp;</p><h2 style="text-align: justify;"><span style="font-size: 14pt;"><strong><span data-preserver-spaces="true">Types of Gear Box</span></strong></span></h2><ul style="text-align: justify;"><li style="list-style-type: disc;"><span data-preserver-spaces="true">Helical gearbox</span></li><li style="list-style-type: disc;"><span data-preserver-spaces="true">Coaxial helical inline gearbox</span></li><li style="list-style-type: disc;"><span data-preserver-spaces="true">Skew bevel helical gearbox</span></li><li style="list-style-type: disc;"><span data-preserver-spaces="true">Worm reduction gearboxes</span></li><li style="list-style-type: disc;"><span data-preserver-spaces="true">Sliding&nbsp;</span><span data-preserver-spaces="true">mesh type</span><span data-preserver-spaces="true">&nbsp;</span><span data-preserver-spaces="true">gear box</span></li></ul><p style="text-align: justify;">&nbsp;</p><h2 style="text-align: justify;"><span style="font-size: 14pt;" data-preserver-spaces="true">Applications of Gearbox</span></h2><p style="text-align: justify;"><span data-preserver-spaces="true">Gears are required to keep the engine at rotational speeds, which creates a desirable amount of power across a wide range of road speeds. Generally, the faster an engine turns, the more fuel it consumes and the more power it makes. Engines are also only capable of rotating to a maximum speed.</span></p><p style="text-align: justify;"><span data-preserver-spaces="true">The various areas where the gearbox&nbsp;</span><span data-preserver-spaces="true">is used</span><span data-preserver-spaces="true">&nbsp;are:</span></p><ul style="text-align: justify;"><li style="list-style-type: disc;"><span data-preserver-spaces="true">Marine</span></li><li style="list-style-type: disc;"><span data-preserver-spaces="true">Industrial equipment</span></li><li style="list-style-type: disc;"><span data-preserver-spaces="true">Steel Plant</span></li><li style="list-style-type: disc;"><span data-preserver-spaces="true">Railway</span></li><li style="list-style-type: disc;"><span data-preserver-spaces="true">Power Plants</span></li><li style="list-style-type: disc;"><span data-preserver-spaces="true">Cooling Towers</span></li><li style="list-style-type: disc;"><span data-preserver-spaces="true">Automobiles &amp;&nbsp;</span><span data-preserver-spaces="true">etc</span><span data-preserver-spaces="true">.</span></li></ul><p style="text-align: justify;">&nbsp;</p><h2 style="text-align: justify;"><span style="font-size: 14pt;"><strong><span data-preserver-spaces="true">Reasons for Gearbox Failure</span></strong></span></h2><p style="text-align: justify;"><span data-preserver-spaces="true">Gearbox failure can&nbsp;</span><span data-preserver-spaces="true">causes</span><span data-preserver-spaces="true">&nbsp;a complete machinery breakdown, expensive both in their subsequent repair and lost output.</span></p><ul style="text-align: justify;"><li style="list-style-type: disc;"><span data-preserver-spaces="true">Inadequate lubrication</span></li><li style="list-style-type: disc;"><span data-preserver-spaces="true">Contamination</span></li><li style="list-style-type: disc;"><span data-preserver-spaces="true">Installation errors</span></li><li style="list-style-type: disc;"><span data-preserver-spaces="true">Overload</span></li><li style="list-style-type: disc;"><span data-preserver-spaces="true">Handling errors</span></li></ul><p style="text-align: justify;">&nbsp;</p><p style="text-align: justify;"><span data-preserver-spaces="true">The&nbsp;</span><span data-preserver-spaces="true">major</span><span data-preserver-spaces="true">&nbsp;causes are inadequate lubrication caused by underfilling, incorrect specification, mixing or incompatibility, incorrect lubrication and intervals, deteriorated grease oil, water contamination, and particular contamination.</span></p><p style="text-align: justify;"><span data-preserver-spaces="true">Water contamination essentially&nbsp;</span><span data-preserver-spaces="true">disables</span><span data-preserver-spaces="true"> the lubricating properties of the oil &amp; can cause forming of the oil. Water in the oil can result from condensation or falling seals, allowing water to enter.</span></p><p style="text-align: justify;"><span data-preserver-spaces="true">Overloaded components cause 7% of failures by exceeding design limits for load, speed, or temperature. The greater the overload, the shorter the component life.</span></p><p style="text-align: justify;"><span data-preserver-spaces="true">The primary symptoms of overload include noise, vibration, and increased temperature.</span></p><p style="text-align: justify;"><span data-preserver-spaces="true">Metallic&nbsp;</span><span data-preserver-spaces="true">chips</span><span data-preserver-spaces="true">&nbsp;debris and reduced equipment performance.</span></p><p style="text-align: justify;">&nbsp;</p><p style="text-align: justify;">&nbsp;</p><p><em>This article was contributed by our expert <a href="https://www.linkedin.com/in/rachakonda-ramana-04303235/" target="_blank" rel="noopener">Rachakonda Ramana</a>&nbsp;</em></p><p><em>&nbsp;</em></p><h3>&nbsp;</h3><h3><span style="font-size: 18pt;">Frequently Asked Questions Answered by Rachakonda Ramana</span></h3><p style="text-align: justify;">&nbsp;</p><h2 style="text-align: justify;"><span style="font-size: 12pt;">1. Which materials used to make a gearbox?</span></h2><p style="text-align: justify;">The materials used to make gears usually depends on the applications. The gears can be manufactured from either metallic or non-metallic materials. Metallic gears can usually be obtained from steel, cast iron, bronze etc.</p><p style="text-align: justify;">A few of the most commonly used materials are EN353, SAE8620H and 20MnCr5. They are arranged according to their strength in descending order. The strength of materials is directly proportional to their cost.</p><p style="text-align: justify;">So, if you require a gear for high torque application you go for EN353.</p><p style="text-align: justify;">&nbsp;</p><h2 style="text-align: justify;"><span style="font-size: 12pt;">2. How do you maintain a gearbox?</span></h2><ul style="text-align: justify;"><li>Keep your gearbox lubricated at all times</li><li>Always keep your gearbox clean</li><li>Ensure proper cooling of your gearbox</li><li>Analyze the vibrations of your gearbox.</li></ul><p style="text-align: justify;">&nbsp;</p><h2 style="text-align: justify;"><span style="font-size: 12pt;">3. Which bearing is used in gearbox?</span></h2><ul style="text-align: justify;"><li>Cylindrical roller bearing</li><li>Spherical roller bearing</li><li>Tapered roller bearing</li></ul><p style="text-align: justify;">&nbsp;</p><p>&nbsp;</p><p>&nbsp;</p>