Gears are crucial components to many machines, so you want them to last a long time, and hold up under pressure—ideally forever. But no matter how expertly you’ve designed or manufactured a gear, it’s going to have a finite lifespan. Gears suffer from wear and tear like any other physical object, so how long, exactly, can you expect a gear to last?
Main Factors to Consider
As you might expect, the answer isn’t clear-cut or universal. Gears have very different lifespans depending on the following variables and then some:
- Gear type. Not all types of gears wear evenly. Spur gears, for example, only have one point of contact, and therefore suffer wear faster than their helical counterparts, which use gradually connecting spiral teeth to produce a smoother motion.
- Gear application. The application you’re using the gear for also matters. For example, some gear applications require the gear to be used at high speeds or under intense pressure; obviously, these will wear down the gear in question faster than a calmer, less intense application. Selection of the appropriate lubrication is also critical.
- Materials. There are dozens of different materials that can be used for gear manufacturing, and some of them are more resistant to wear than others. Cast iron and steel are very durable, and can hold up to extreme circumstances well, while plastic is more malleable, and will have a shorter lifespan as a result. Hardening the gear teeth should increase the life of the gear.
- The engineering process. The gear’s lifespan also depends on how it was designed and manufactured. If it was reverse engineered from an existing gear, for example, it probably can’t be precisely replicated, and its tiny flaws could make it wear down faster than the original gear in the system.
Overall, your gear’s lifespan will depend on how you have it manufactured and what you’re going to be using it for. A gear could last anywhere from a few years to centuries, depending on the conditions, so work to understand your application before proceeding. If you’re ready to get more information about the gear manufacturing process, contact Federal Gear today!