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First, the gear reversal method: When a single face of the gear is worn, if the structure allows, the gear can be flipped 180 degrees to use the unworn side. However, it's best to replace it in pairs or manufacture a new one to ensure proper meshing and prevent further damage. This method is ideal for gears with minor wear and can significantly extend their service life.
Second, the ring gear insertion method: For multi-toothed gears that are assembled together, each tooth may experience different levels of wear. If some teeth are damaged, the worn section can be replaced by inserting a new ring gear. The damaged area is first prepared, and a new ring gear is pressed onto the gear. To prevent the ring gear from loosening, spot welding can be applied around the joint, or small studs can be drilled and fixed in place for added stability.
Third, the tooth insertion method: This technique is suitable for low-load and low-speed gears where individual teeth are damaged. The worn part of the gear is machined to create a trapezoidal groove on a planer. A new tooth blank is then inserted into the groove with some tension, followed by welding and machining to shape the tooth properly. This method ensures a strong and durable repair.
Fourth, the surfacing welding method: When gear teeth are severely worn or both sides are damaged beyond acceptable limits, the affected areas can be repaired using surfacing welding. This involves overlaying one or more layers of metal onto the gear surface. The process can be done through arc welding or gas welding, depending on the material and condition. Surfacing is an efficient and reliable repair method that restores the gear’s original dimensions and strength.
Fifth, the screw-tooth method: In cases where a tooth is completely worn out, the damaged tooth can be removed and the area cleaned. Using a vernier caliper, measure the root thickness and level the damaged area with a file. Choose a screw with a diameter matching the root thickness, ensuring the thread length is at least 1.5 to 2 cm. Drill a hole in the damaged area using a bench drill, then tap it with a tap. Insert the screw and tighten it. Cut off the excess screw above the tooth top with a hacksaw, then machine the tooth to match the original profile using a crusher. This method provides a cost-effective solution for repairing damaged gears.