GEAR FAILURES

Scuffing
Dr.-Ing. Klaus Michaelis

Forschungsstelle für Zahnräder und Getriebebau

Gear Research Centre
Head of the Institute: Prof. Dr.-Ing. B.-R. Höhn

TU München Course at the University of Ljubljana Michaelis

B.-R. Höhn

TU München Typical Load Carrying Capacity Limits Michaelis

B.-R. Höhn of Case Carburized Gears 4/144.12.28

1
 continuous abrasive wear

instantaneous adhesive scoring

scuffing

fatigue micropitting
pitting

TU München Michaelis
Flank Failures in Gears 9/111.05.18
B.-R. Höhn

TU München Michaelis
Light Scoring Marks 10/144.03.24
B.-R. Höhn

2
TU München Michaelis
Scoring with one Scuffing Stripe 15/144.03.24
B.-R. Höhn

TU München Michaelis
Scuffing Stripes 16/144.03.24
B.-R. Höhn

3
TU München Michaelis
Light Scuffing 16/144.03.24
B.-R. Höhn

TU München Michaelis
Severe Scuffing 20/144.03.24
B.-R. Höhn

4
 acc. Collenberg

TU München Photos, Profile and Lead Diagrams of Michaelis

B.-R. Höhn Corresponding Scuffing Failures on Pinion and Gear 4/125.01.20

acc. Michaelis

TU München Material Transfer on a Scuffed Pinion Flank Michaelis

1/59.15.18
B.-R. Höhn

5
 SEM photo

micro section
acc. Collenberg

TU München Material Transfer in the Addendum of the Pinion Michaelis

3/125.02.20
B.-R. Höhn

acc. Collenberg

TU München Typical SEM Photos of Transferred Material Michaelis

B.-R. Höhn at High Speed Conditions 3/125.02.20

6
 acc. Michaelis

TU München Mechanism of Lubrication of Oils with Additives Michaelis

B.-R. Höhn (schematic) 3/59.06.5

load
gravimetric stage
visual

scuffing torque pinion

FVA oil no. acc. Michaelis

TU München Influence of Viscosity on Scuffing Load Capacity Michaelis

B.-R. Höhn for Pure Mineral FVA Reference Oils 3/111.04.17

7
 load
stage

acc. Michaelis

TU München Influence of TCP Additive Concentration on Michaelis

B.-R. Höhn Scuffing Load Capacity 4/111.04.17

acc. Collenberg

TU München Influence of Type of Additive on Michaelis

B.-R. Höhn Scuffing Load Capacity of Turbine Oils 7/125.02.20

8
 acc. Lechner

TU München Influence of Relative Sliding Michaelis

B.-R. Höhn on Scuffing Load Capacity 11/111.05.24

acc. Prexler

TU München Michaelis
Measurement of Surface Roughness 4/100.05.18
B.-R. Höhn

9
 acc. Prexler

TU München Measurement of Surface Roughness Michaelis

B.-R. Höhn Determination of Parameters of Material Portion 5/100.05.18

acc. Michaelis

TU München Influence of Surface Roughness Michaelis

B.-R. Höhn on Scuffing Load Capacity 13/59.15.18

10
 acc. Michaelis

TU München Influence of Copper Plating Michaelis

B.-R. Höhn on Scuffing Load Capacity 15/59.15.18

TU München Influence of Tip Relief Michaelis

B.-R. Höhn on Scuffing Load Capacity 7/59.15.18

11
TU München Influence of Austenite Content Michaelis
B.-R. Höhn on Scuffing Load Capacity 14/59.15.18

acc. Michaelis

TU München Influence of Oil Temperature Michaelis

B.-R. Höhn on Scuffing Load Capacity 6/144.12.28

12
 acc. Schlenk

TU München Michaelis
Temperature Distribution and Film Formation 22/133.02.29
B.-R. Höhn

TU München Influence Factors on Scuffing Load Capacity Michaelis

42/106.03.18
B.-R. Höhn Transmittable Torque

13
TU München Gear Oil Testing Machines Michaelis
B.-R. Höhn Principles 10/73.04.13

acc. Wirtz

TU München Michaelis
Scuffing Load Ratings in Different Test Rigs 11/73.04.13
B.-R. Höhn

14
 acc. Michaelis

TU München Michaelis
Scuffing Load Ratings in Different Test Rigs 17/59.11.12
B.-R. Höhn

TU München FZG Back-to-Back Gear Test Rig Michaelis

7/144.12.28
B.-R. Höhn Schematic

15
TU München Michaelis
FZG Back-to-Back Gear Test Rig
B.-R. Höhn

TU München Michaelis
Geometrical Data of Test Gears Type A 1/144.03.24
B.-R. Höhn

16
TU München Load and Speed Distribution of Test Gears Type A Michaelis
11/59.15.18
B.-R. Höhn

TU München Michaelis
Test Gear Box
B.-R. Höhn

17
TU München Michaelis
Standard FZG Scuffing Test A/8,3/90 5/73.09.14
B.-R. Höhn

TU München Main Influence Factors on the Result Michaelis

B.-R. Höhn of an FZG Scuffing Test 9/144.03.24

18
TU München Michaelis
Load Stages of the FZG Gear Oil Test 4/144.03.24
B.-R. Höhn

TU München Result of an FZG Standard Scuffing Test A/8,3/90 Michaelis

6/73.09.14
B.-R. Höhn Gravimetric Method

19
TU München Michaelis
Results of the FZG Scuffing Test A/8,3/90 8/73.09.14
B.-R. Höhn

TU München Frequently Used Test Modifications Michaelis

8/144.03.24
B.-R. Höhn of the FZG Scuffing Test A/8,3/90

20
TU München Michaelis
Test Regime of Standard Scuffing Tests 1/144.10.27
B.-R. Höhn

TU München Modifications of the Michaelis

7/144.03.24
B.-R. Höhn Standard FZG Scuffing Test A/8,3/90

21
TU München Michaelis
Comparison of Different Scuffing Test Methods 2/144.10.27
B.-R. Höhn

TU München Michaelis
Test Lubricants 4/144.10.27
B.-R. Höhn

22
 A/8.3/90 A10/16.6R/90 S-A10/16.6R/90

800
700 14
13
600
12
500
11
400
10
300 9
8
200 7
6
100
4
0 2
C1 C2 C3 G1A G3 G4 G6 G7
GL3 GL4 GL4+ GL5

TU München Michaelis
Results of Industrial and Transmission Gear Oils 11/144.15.31
B.-R. Höhn

TU München Results of Transmission Oils Michaelis

6/144.10.27
B.-R. Höhn In the Shock Test S-A10/16,6R/90

23
 1000

900
S-A10/16,6R/90
scuffing temperature ϑint S in °C

800
A10/16,6R/90
700
A/8,3/90
600

500

400

300

200

100

0
3 4 5 6 7 8 9 10 11 12 13 14
load stage

TU München Scuffing Integral Temperature Michaelis

5/144.10.27
B.-R. Höhn for Different Test Methods

TU München Temperature Distribution along the Path of Contact Michaelis

5/59.15.18
B.-R. Höhn

24
TU München Comparison of Total Contact Temperature Michaelis
4/59.10.13
B.-R. Höhn and Integral Temperature Criteria

TU München Scuffing Load Carrying Capacity Rating Michaelis

4/73.05.11
B.-R. Höhn According to Integral Temperature Criteria

25
TU München Michaelis
B.-R. Höhn
Permissible Integral Temperature 5/73.05.11

TU München Michaelis
B.-R. Höhn
Scuffing Integral Temperature from FZG Test A/8,3/90 5/73.05.11

26
 gear

pinion

TU München Michaelis
B.-R. Höhn
Scuffing of Pinion and Gear of a Railway Gearset 35,36/106.03.17

design point for

scuffing calculation

driving

breaking
pinion torque

locomotive
speed

pinion speed

TU München Michaelis
Torque-Speed Diagram of a Locomotive 34/106.03.17
B.-R. Höhn

27
TU München Michaelis
B.-R. Höhn
Main Data of a Railway Gearset 5/111.08.19

28