Abstract

This paper presents a recent gearbox failure in a rail transit vehicle. The damaged components, pinion bearing and large gear, were analyzed from macroscopic, microscopic, and performance perspectives. Through a comprehensive analysis of the test results, the two main factors causing the failure were identified: fatigue damage of the pinion bearing due to abnormal external load and the presence of brittle non-metallic inclusions, which initiated fatigue cracks leading to gear drop blocks. To improve gearbox reliability, suggestions were made to optimize operating conditions and improve the metallurgical purity of metal materials.

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