After the melt pump failed, the following damage characteristics were observed upon disassembly:
One end of the driven gear shaft of the high-temperature melt pump was fractured, while the other end showed visible cracks.
More than three teeth of the driven gear were broken, all of which were "uprooted" from the root.
The sliding bearing of one driven gear shaft was severely seized and completely cracked after disassembly.
The mating surfaces of the driven gears were severely worn.
The front or rear cover plate of the high-temperature melt pump showed noticeable friction marks at the locations corresponding to the driven gear shafts.
The roots of the remaining unbroken driven gears exhibited visible cracks.
To address these issues in the design of the melt pump, the following improvements should be considered:
Enhance the stiffness of the driven gear shaft.
Increase the bending fatigue strength at the root of the driven gears.
Improve the contact fatigue strength of the working surfaces of the driven gears.
Appropriately increase the clearance between the shaft ends and the cover plates of the high-temperature melt gear pump to prevent friction between the shaft ends and the cover plates. This friction generates excessive heat, which can carbonize the melt used for lubrication and block the lubrication channels.
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