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Why Gears Wear Out
And How to Prevent Gear Failure in Industrial Machinery
Gear failure is one of the most disruptive and expensive problems in industrial machinery. When a gear wears out, it doesn’t fail quietly — it takes entire systems down with it.
Production stops. Costs rise. Downtime stretches longer than expected.
The frustrating part?
Most gear failures are completely preventable.
At Pullies & Gears Sales, we supply precision-engineered gears and work closely with our manufacturing partners to ensure every component is built for performance, durability, and long service life.
At Pullies & Gears Sales, we specialise in supplying high-strength industrial pulleys and gears
The 6 Most Common Causes of Gear Wear
Misalignment
When gears are not perfectly aligned, teeth do not mesh correctly.
This leads to:
- Uneven load distribution
- Vibration and noise
- Accelerated wear
Overloading
Exceeding a gear’s design limits causes:
- Tooth deformation
- Cracking and breakage
- Reduced lifespan
Often caused by incorrect gear ratios or pushing machinery beyond capacity.
Poor Lubrication
Lubrication is critical.
Without it:
- Metal contacts metal
- Heat builds up
- Surfaces degrade rapidly
👉 Dry gears fail fast.
Contamination
Dust, moisture, and debris cause:
- Abrasive wear
- Corrosion
- Lubricant breakdown
Incorrect Material Selection
Using the wrong material leads to:
- Premature wear (too soft)
- Cracking (too brittle)
Incorrect Gear Ratio
A mismatched ratio causes:
- Overloading
- Inefficiency
- Excessive wear
Why Gears Wear Out and How to Prevent Gear Failure in Industrial Machinery
How to Fix Gear Wear — The Right Way
Use Precision-Cut Gears
Accuracy matters.
We supply gears manufactured to exact tolerances using high-quality materials like:
- EN8 (C45) – Strong, reliable, and widely used
- EN24 – High-strength alloy for heavy-duty applications
- EN36 – Case-hardened for extreme wear resistance
At Pullies & Gears Sales, we specialise in supplying high-strength industrial pulleys and gears
The 6 Most Common Causes of Gear Wear
High-Performance Gear Materials
EN24 — Built for Heavy-Duty Performance
Ideal for:
- High torque systems
- Mining and industrial machinery
- Shafts and axles
Key benefits:
- Exceptional strength
- High fatigue resistance
- Shock-load capability
EN36 — Maximum Wear Resistance
Designed for:
- High-speed gearboxes
- Precision gear systems
- Continuous heavy load environments
Key benefits:
- Hardened outer surface
- Tough internal core
- Long service life
Why Material Choice Matters
Choosing the correct steel reduces:
- Tooth wear
- Pitting
- Cracking
- Heat damage
- Unexpected downtime
👉 The right material = longer lifespan + lower costs
Expert Support from Our Manufacturing Partners
You’re not just buying a gear — you’re getting a solution.
We help you:
- Diagnose gear failure
- Select the correct material
- Match gear ratios
- Choose proper lubrication
- Prevent repeat failures
Lubrication: The Silent Protector
Using the correct lubricant:
- Reduces friction
- Dissipates heat
- Prevents corrosion
- Extends gear life
👉 Lubrication is not optional — it’s essential.