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Last year a customer in Shandong contacted us: a worm gearbox on an imported production line was worn out, the OEM had discontinued the model, and spare parts were unavailable. The line had already been down for a week. By reverse-engineering the worn parts and remanufacturing a set to the original parameters, we restored production in about half a month.
1. Customer situation
The customer builds building-materials equipment. The imported worm gearbox had been in service for nearly ten years. Clearance had been increasing and positioning accuracy was degrading. After teardown, the worm-wheel tooth flanks were heavily worn and the worm was also damaged.
The problem: the machine had been imported a decade earlier; the OEM had discontinued that model, and no generic domestic replacement existed. Several reducer makers the customer approached said they could not make it—there were no drawings and the parameters were unknown.
2. How we handled it
The customer shipped the worn parts to us. We measured the following:
– Worm: outside diameter, lead, number of starts, tooth form, and axial dimensions
– Worm wheel: outside diameter, bore, number of teeth, face width
– Center distance: measured installed center distance
Tooth-form parameters were critical. Using a gear measuring center, we measured the worm’s axial pitch and pressure angle and back-calculated the module and pressure angle.
3. Manufacturing process
Once parameters were confirmed, we selected a tin-bronze worm wheel paired with a 40Cr quenched-and-tempered worm. Steps:
1. Rough-turn the worm OD and mill the tooth form
2. Harden to HRC48–52
3. Grind the worm tooth flanks to Ra0.8
4. Cut the worm wheel with a hob matched to those parameters
5. Run-in as a matched pair and check the contact pattern
The contact pattern must sit in the middle of the tooth flank, with contact ratio along tooth height no less than 60% and along tooth length no less than 70%.
4. Delivery result
After machining we shipped the set. The customer installed it and ran a trial: clearance was normal and noise was similar to the original. Production resumed; nearly a year later the customer reported stable operation.
This case shows that discontinued imported equipment is manageable if parameters can be measured accurately and the pair is machined as a matched set. Dezhou Xinmi Machinery has years of reverse-engineering experience and can remanufacture worn worm sets to original parameters.
