SUMMER TRAINING

ON

Electric Loco Shed-North

Central Railways

TOPIC:

GEAR FAILURE

Submitted By:
Rajeev Yadav

Submitted To:
MR. Sulabh Nalwaya
(Lecturer)

Contents:
About Electric loco shed
Gear
Types Of Gear
Gear failure
Recognition Of gear
failure
Causes of gear failure

About Electric Loco Shed

The electric loco shed, Kanpur was

established in 1965 with the
Electricification of Mughalsarai-kanpur.
The shed started functioning with a
meager holding of 11 imported WAM-1
type locomotives for passenger services.
Present holding of shed is 201
locomotives (43-WAP4, 153WAG7, 02WAG-9, &3-WAM4

GEA
R
A gear or cogwheel is
a rotating machine part having cut teeth,
or cogs, which mesh with another toothed
part in order to transmit torque.

TYPES OF GEAR
Spur Gears
Spur gears are by far the most common
type of gear and with the exceptions of
the "cog" the type of gear that has been
around the longest
Spur gears have teeth that run
perpendicular to the face of the
gear.

Helical Gears
Helical gears are very similar
to spur gears except the teeth
are not perpendicular to the
face. The teeth are at an angle
to the face giving helical gears
more tooth contact in the same
area.
Helical gears tend to run quieter and
smoother than spur gears due to the
increased number of teeth in constant
contact at any one period of time

GEAR FAILURE
RECOGNITION Of GEAR FAILURE :

1. A GEAR has failed when it can no longer

efficiently do the job for which it was
designed.
2. Cause of failure may range from excessive
wear to catastrophic breakage.

CAUSES OF GEAR FAILURE:

POLISHING.
WEAR.
PITTING.
SCORING
FROSTING
FRACTURE.
PLASTIC FLOW.
RIPPLING.
RIDGING

Polishing
Polishing is a very slow
wearing-in process in which the
asperities of the contacting
surfaces are gradually worn off
until a very fine, smooth surface
develops.
Cause: This condition is usually
caused by metal to-metal
contact
during
operation.

WEAR:
A surface phenomenon
in which
layers of metal are removed, or
"worn away," more or less
uniformly
from the con tacting
surfaces of the gear teeth
Cause: Foreign material
in the lubrication
system ordinarily
causes abrasive wear.

PITTING:
A surface fatigue failure which
occurs when the endurance
limit of
the material is exceeded, a failure of
this nature depends on surface contact
stress and number of stress cycles.

Cause: Pitting is usually caused by

gear tooth surfaces not properly

conforming with each other

or not fitting together properly

SCORING:
Rapid wear resulting from a
failure of the oil film due to
overheating
of the mesh,
permitting
metal-to-metal
contact; this contact produces
alternate welding and tearing
which removes metal rapidly
from
the tooth surfaces

Frosting :
Frosting occurs in the early stages of
scoring. Usually the dedendum section of
the driving gear is the first to show
signs of surface distress, al though
frosting can first show up on the
addendum section.
Cause: Frosting is caused by heat
in the mesh, which results in
only marginal lubrication.

FRACTURE:
Failure caused by breakage of a
whole tooth or a substantial
portion
of a tooth; this can result from
overload or, more commonly,
by
cyclic stressing of the gear tooth
beyond the endurance limit of the
material.
Cause: Failures of this kind are often
caused by deficiencies in the gear
tooth which result in a high stress
concentration at a particular area.

PLASTIC FLOW:
It is caused by high contact
stresses and the rolling and
sliding action of the mesh.
It is usually associated
with the softer gear
materials

CAUSES: It often occurs in heavily

loaded case-hardened
and throughhardened
gears

RIDGING:
This is the formation of deep
ridges by plastic flow of surface
and subsurface material.

It shows definite peaks and

valleys or ridges across the tooth
surface in the direction of
sliding.

Cause: Ridging is caused by the plastic flow of surface

and subsurface material due to high contact
compressive stresses and high relative sliding
velocities.

REFERENCE:
N.P. SINGH (S.S.E.)
Wikipedia
Goggle
www. Northern central railway.com

THANK YOU..