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First, the gear reversal method: When a single face of the gear tooth is worn, and the structure allows, the gear can be flipped or rotated 180 degrees to use the opposite side. However, it's best to replace the gear in pairs or manufacture a new one to ensure proper meshing and performance. This approach helps extend the life of the gear and maintains the integrity of the gear system.
Second, the gear ring insertion method: In cases where the gear is composed of multiple segments, such as a composite or segmented gear, individual sections may wear differently. If a section becomes damaged, the worn portion can be replaced by inserting a new gear ring. The damaged area is first prepared, and a new ring gear is pressed into place. To prevent loosening, the joint between the ring gear and the main gear can be spot-welded or secured with threaded studs for added stability.
Third, the tooth insertion method: For low-load, low-speed gears that have only a few teeth damaged, the broken teeth can be repaired by machining a trapezoidal groove into the gear root using a planer. A new tooth blank is then inserted into the groove with some tension, followed by welding and final machining to restore the tooth profile. This method is effective for minor damage and can save the gear from complete replacement.
Fourth, the surfacing welding method: When gear teeth are worn or damaged on both sides beyond acceptable limits, the affected areas can be repaired by overlaying one or more layers of metal through welding. This technique involves either arc welding or gas welding, depending on the material and condition of the gear. Surfacing not only restores the gear’s original dimensions but also improves its durability and performance, making it a practical and efficient repair option.
Fifth, the screw-tooth method: If a gear has severely worn or broken teeth, the damaged portion can be removed and cleaned. Using a vernier caliper, measure the thickness of the remaining tooth root. Then, clean and level the damaged area with a cutting tool. Select a screw with an appropriate diameter, ensuring the thread length is at least 1.5 to 2 cm. Drill a hole in the damaged area and tap it to fit the screw. Once the screw is tightened, trim any excess length above the gear teeth using a hacksaw. Finally, use a crusher or shaping tool to re-form the tooth to match the original profile, restoring the gear's functionality.