FMEA for Gearboxes

We define gearbox functions: transmit torque at specified speed ratio, contain lubricant, and maintain gear mesh alignment. Gear failure modes per AGMA 1010 include: initial pitting, progressive pitting, spalling, micropitting, scuffing, adhesive wear, abrasive wear, polishing wear, tooth bending fatigue, tooth bending overload, case crushing, and plastic deformation. Bearing modes include: rolling contact fatigue, cage failure, contamination damage, and lubrication failure. Seal modes: lip wear, elastomer degradation, and shaft wear under seal. Lubrication modes: oil degradation, contamination ingress, loss of oil level, and cooler failure. Severity ratings account for gearbox repair cost, production loss, and secondary damage potential. Occurrence ratings use your failure data supplemented by AGMA reliability data. Detection ratings evaluate vibration gear mesh analysis capability and oil analysis program maturity. Task selection assigns vibration monitoring for surface fatigue modes, oil debris monitoring for wear modes, and scheduled inspection for overload and case crushing modes. The FMEA provides the technical basis for gearbox monitoring and maintenance strategy.