Abstract
Gearbox of a conveyor belt at a sinter plant failed prematurely during service. It led to an interruption in the supply of raw materials for sinter making and therefore affected the productivity. Detailed analysis of the failure of the gearbox was carried out. Observation reveals material chip off from teeth portion with multiple beach marks and striations confirming fatigue mode of failure. However, no gross metallurgical abnormality was observed as the material was supplied in quenched and tempered condition with a suitable case depth in teeth without any discernible nonmetallic inclusions. This directed the investigation toward maintenance-related issues, and it came out that the viscosity of the lubricant in use was significantly lower. Also, investigation of earlier ferrography suggested that the lubricant contained dark metal oxides and wear debris which may lead to inefficient lubrication. Therefore, it was concluded that gear failed in fatigue mode due to lubrication related issues.
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