Failure diagnostics: reading the damage on a gear<\/title>\n\n <link rel=\"preconnect\" href=\"https:\/\/fonts.googleapis.com\">\n <link rel=\"preconnect\" href=\"https:\/\/fonts.gstatic.com\" crossorigin=\"\">\n <link href=\"https:\/\/fonts.googleapis.com\/css2?family=Inter:wght@400;500;600;700&display=swap\" rel=\"stylesheet\">\n\n <style>\n *, *::before, *::after { box-sizing: border-box; margin: 0; padding: 0; }\n\n :root {\n --green: #1a6b3c;\n --green-dark: #0f4a28;\n --green-mid: #2d8a55;\n --green-light: #e8f4ed;\n --green-xlight: #f2faf5;\n --amber: #b45309;\n --amber-light: #fef3c7;\n\n --bg: #ffffff;\n --bg-soft: #f8f9fa;\n --bg-muted: #f1f3f5;\n --border: #e5e7eb;\n --border-mid: #d1d5db;\n\n --text-primary: #111827;\n --text-secondary: #4b5563;\n --text-muted: #9ca3af;\n\n --radius-sm: 6px;\n --radius-md: 8px;\n --radius-lg: 12px;\n --shadow-sm: 0 1px 3px rgba(0,0,0,.06), 0 1px 2px rgba(0,0,0,.04);\n --shadow-md: 0 4px 12px rgba(0,0,0,.08), 0 2px 4px rgba(0,0,0,.04);\n }\n\n body { min-height: 100vh; 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}\n\n .badge {\n display: inline-block;\n font-size: 12px;\n font-weight: 600;\n padding: 2px 8px;\n border-radius: 20px;\n background: var(--green-light);\n color: var(--green-dark);\n }\n\n \/* ============================================================\n RESPONSIVE\n ============================================================ *\/\n @media (max-width: 900px) {\n .article-body { flex-direction: column; padding: 20px 20px 48px; }\n }\n \n \/* Glossary tooltips *\/\n .glossary-term {\n border-bottom: 1px dotted var(--green);\n color: var(--green);\n font-style: italic;\n cursor: help;\n }\n .glossary-tooltip {\n position: fixed;\n z-index: 9999;\n background: #fff;\n border: 1px solid var(--border-mid);\n border-radius: var(--radius-md);\n box-shadow: var(--shadow-md);\n padding: 10px 14px;\n max-width: 300px;\n font-family: 'Inter', sans-serif;\n font-size: 13px;\n }\n .glossary-tooltip__title {\n font-weight: 600;\n color: var(--text-primary);\n margin-bottom: 4px;\n }\n .glossary-tooltip__def {\n font-size: 12.5px;\n color: var(--text-secondary);\n line-height: 1.6;\n }\n .glossary-tooltip__tag {\n display: inline-block;\n margin-top: 6px;\n font-size: 9px;\n font-weight: 600;\n padding: 2px 7px;\n border-radius: 20px;\n background: var(--green-light);\n color: var(--green-dark);\n text-transform: uppercase;\n letter-spacing: 0.04em;\n }\n\n <\/style>\n<\/head>\n<body>\n\n<div id=\"tt-gioco-di-flanchi-backlash\" class=\"glossary-tooltip\" hidden=\"\">\n <div class=\"glossary-tooltip__title\">Backlash<\/div>\n <div class=\"glossary-tooltip__def\">Free clearance between the flanks of two mating teeth, measured at the pitch circle. It prevents jamming due to thermal expansion or assembly errors.<\/div>\n <span class=\"glossary-tooltip__tag\">Glossary<\/span>\n<\/div>\n<div id=\"tt-pitting\" class=\"glossary-tooltip\" hidden=\"\">\n <div class=\"glossary-tooltip__title\">Pitting<\/div>\n <div class=\"glossary-tooltip__def\">Form of surface wear caused by contact fatigue. It manifests as micro-craters on tooth flanks resulting from cyclic Hertzian contact stress.<\/div>\n <span class=\"glossary-tooltip__tag\">Glossary<\/span>\n<\/div>\n<div id=\"tt-scuffing\" class=\"glossary-tooltip\" hidden=\"\">\n <div class=\"glossary-tooltip__title\">Scuffing<\/div>\n <div class=\"glossary-tooltip__def\">Damage caused by localised adhesion between tooth flanks following breakdown of the lubricant film. It occurs at high speeds and under heavy loads.<\/div>\n <span class=\"glossary-tooltip__tag\">Glossary<\/span>\n<\/div>\n\n <div class=\"article-page\">\n <div class=\"article-body\">\n <div class=\"article-body__main\"><script type=\"application\/ld+json\">\n{\n \"@context\": \"https:\/\/schema.org\",\n \"@graph\": [\n {\n \"@type\": \"TechArticle\",\n \"@id\": \"#article\",\n \"headline\": \"Failure diagnostics: reading the damage on a gear\",\n \"description\": \"A technopolymer gear doesn't break in silence. 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Before the final failure, the teeth already tell what’s going wrong: a few minutes of visual inspection are enough to read the cause and know what to correct.<\/p>\n\n<figure class=\"article__figure\">\n <img src=https:\/\/shop.stagnoligears.com\/wp-content\/uploads\/rottura-dente-ingranaggio.webp alt=\"Gear tooth root fracture\" \/>\n <figcaption>Gear tooth root fracture<\/figcaption>\n<\/figure>\n\n<h2 class=\"article__h2\" id=\"why-do-diagnostics\">\n <span class=\"article__h2-icon\"><svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"16\" height=\"16\" viewBox=\"0 0 24 24\" fill=\"none\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"><circle cx=\"11\" cy=\"11\" r=\"8\"><\/circle><line x1=\"21\" y1=\"21\" x2=\"16.65\" y2=\"16.65\"><\/line><\/svg><\/span>\n Why do diagnostics\n<\/h2>\n<p class=\"article__p\">When a gear breaks, the natural reaction is to replace it. But doing so without analyzing the type of damage means almost certainly seeing the problem reappear after a few hundred hours. Each damage picture corresponds to a specific cause and a precise corrective action.<\/p>\n\n<figure class=\"article__figure\">\n <img src=https:\/\/shop.stagnoligears.com\/wp-content\/uploads\/rottura-dente.webp alt=\"Primary gear tooth failure modes\" \/>\n <figcaption>Microscopic analysis of the primary gear tooth failure modes<\/figcaption>\n<\/figure>\n\n<h2 class=\"article__h2\" id=\"pitting-surface-fatigue\">\n <span class=\"article__h2-icon\"><svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"16\" height=\"16\" viewBox=\"0 0 24 24\" fill=\"none\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"><path d=\"M6 18h8\"><\/path><path d=\"M3 22h18\"><\/path><path d=\"M14 22a7 7 0 1 0 0-14h-1\"><\/path><path d=\"M9 14h2\"><\/path><path d=\"M9 12a2 2 0 0 1-2-2V6h6v4a2 2 0 0 1-2 2Z\"><\/path><path d=\"M12 6V3a1 1 0 0 0-1-1H9a1 1 0 0 0-1 1v3\"><\/path><\/svg><\/span>\n Pitting: surface fatigue\n<\/h2>\n<p class=\"article__p\">Appearance: small <strong>craters or pockmarks<\/strong> on the tooth flank, particularly in the zone of the pitch line. The surface looks pitted, as if struck by a punch at several points.<\/p>\n<p class=\"article__p\">Diagnosis: surface fatigue of the material. The micro-cracks form below the surface due to the repeated cycles of contact pressure, and propagate until small fragments of material detach. It’s a phenomenon of progressive degradation.<\/p>\n<p class=\"article__p\">Probable cause: excessive load, with contact pressure exceeding the material’s fatigue limit, or service life exceeded. The gear has worked beyond the design number of cycles.<\/p>\n<p class=\"article__p\">Action: reduce the load, increase the module, evaluate a higher-strength material such as <strong>PA6 reinforced with 30% glass fiber (PA6+30%GF)<\/strong>, or plan periodic replacement as a consumable component.<\/p>\n<h2 class=\"article__h2\" id=\"scuffing-localized-melting\">\n <span class=\"article__h2-icon\"><svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"16\" height=\"16\" viewBox=\"0 0 24 24\" fill=\"none\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"><path d=\"M8.5 14.5A2.5 2.5 0 0 0 11 12c0-1.38-.5-2-1-3-1.072-2.143-.224-4.054 2-6 .5 2.5 2 4.9 4 6.5 2 1.6 3 3.5 3 5.5a7 7 0 1 1-14 0c0-1.153.433-2.294 1-3a2.5 2.5 0 0 0 2.5 3z\"><\/path><\/svg><\/span>\n Scuffing: localized melting\n<\/h2>\n<p class=\"article__p\">Appearance: <strong>streaks parallel<\/strong> to the sliding direction, often with patchy dark or shiny zones. The surface looks smeared or dirtied. In technopolymers it’s common to find residues of melted material in the cavities between teeth.<\/p>\n<p class=\"article__p\">Diagnosis: localized surface melting. The temperature in the contact zone has exceeded the softening temperature of the polymer, melting it locally.<\/p>\n<p class=\"article__p\">Probable cause: excessive operating temperature, insufficient flank <dfn id=\"def-gioco-di-flanchi-backlash\"><span class=\"glossary-term\" data-tooltip=\"tt-gioco-di-flanchi-backlash\" title=\"Free clearance between the flanks of two mating teeth, measured at the pitch circle. It prevents jamming due to thermal expansion or assembly errors.\">backlash<\/span><\/dfn> up to seizing, absent or inadequate lubrication.<\/p>\n<p class=\"article__p\">Action: verify the backlash, check the ambient and operating temperature, evaluate a hybrid pairing (technopolymer-metal or with thermal additives) to improve heat dissipation.<\/p>\n<h2 class=\"article__h2\" id=\"root-fracture\">\n <span class=\"article__h2-icon\"><svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"16\" height=\"16\" viewBox=\"0 0 24 24\" fill=\"none\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"><path d=\"M10.29 3.86L1.82 18a2 2 0 0 0 1.71 3h16.94a2 2 0 0 0 1.71-3L13.71 3.86a2 2 0 0 0-3.42 0z\"><\/path><line x1=\"12\" y1=\"9\" x2=\"12\" y2=\"13\"><\/line><line x1=\"12\" y1=\"17\" x2=\"12.01\" y2=\"17\"><\/line><\/svg><\/span>\n Root fracture\n<\/h2>\n<p class=\"article__p\">Appearance: the tooth is <strong>completely detached<\/strong> from the gear wheel, with a fracture surface at the base.<\/p>\n<p class=\"article__p\">Diagnosis: exceeding the yield limit in bending.<\/p>\n<p class=\"article__p\">Probable cause: a sudden load peak or shock not foreseen at the design stage.<\/p>\n<p class=\"article__p\">Action: verify whether the application presents impulsive loads not considered in the sizing. Evaluate a material with greater resilience or a more robust tooth profile.<\/p>\n<h2 class=\"article__h2\" id=\"plastic-deformation\">\n <span class=\"article__h2-icon\"><svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"16\" height=\"16\" viewBox=\"0 0 24 24\" fill=\"none\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"><line x1=\"18\" y1=\"20\" x2=\"18\" y2=\"10\"><\/line><line x1=\"12\" y1=\"20\" x2=\"12\" y2=\"4\"><\/line><line x1=\"6\" y1=\"20\" x2=\"6\" y2=\"14\"><\/line><\/svg><\/span>\n Plastic deformation\n<\/h2>\n<p class=\"article__p\">Appearance: the teeth are <strong>visibly deformed<\/strong>, bent or with a distorted profile, but not broken.<\/p>\n<p class=\"article__p\">Diagnosis: exceeding the softening temperature under continued load.<\/p>\n<p class=\"article__p\">Probable cause: excessive friction from insufficient clearance or wrong lubrication, or ambient temperature higher than foreseen at the design stage.<\/p>\n<p class=\"article__p\">Action: verify the HDT (Heat Deflection Temperature, the temperature at which the material begins to deform under load) relative to the real operating temperature. Recalculate the minimum clearance.<\/p>\n<h2 class=\"article__h2\" id=\"diagnostic-table\">\n <span class=\"article__h2-icon\"><svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"16\" height=\"16\" viewBox=\"0 0 24 24\" fill=\"none\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"><circle cx=\"12\" cy=\"12\" r=\"10\"><\/circle><\/svg><\/span>\n Diagnostic table\n<\/h2>\n<div class=\"article__table-wrap\">\n<table class=\"article__table\">\n<thead><tr><th>Visible sign<\/th><th>Technical diagnosis<\/th><th>Probable cause<\/th><\/tr><\/thead>\n<tbody><tr><td><dfn id=\"def-pitting\"><span class=\"glossary-term\" data-tooltip=\"tt-pitting\" title=\"Form of surface wear caused by contact fatigue. It manifests as micro-craters on tooth flanks resulting from cyclic Hertzian contact stress.\">Pitting<\/span><\/dfn><\/td><td>Surface fatigue of the material<\/td><td>Excessive load or exceeded life cycles<\/td><\/tr>\n<tr><td><dfn id=\"def-scuffing\"><span class=\"glossary-term\" data-tooltip=\"tt-scuffing\" title=\"Damage caused by localised adhesion between tooth flanks following breakdown of the lubricant film. It occurs at high speeds and under heavy loads.\">Scuffing<\/span><\/dfn><\/td><td>Localized surface melting<\/td><td>Excessive temperature or lack of clearance<\/td><\/tr>\n<tr><td>Root fracture<\/td><td>Exceeding the yield limit<\/td><td>Sudden load peak or shock<\/td><\/tr>\n<tr><td>Plastic deformation<\/td><td>Exceeding the softening temperature<\/td><td>Excessive friction or environment too hot<\/td><\/tr><\/tbody>\n<\/table>\n<\/div>\n<div class=\"infobox infobox--grey\">\n <div class=\"infobox__title\">\n <svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"14\" height=\"14\" viewBox=\"0 0 24 24\" fill=\"none\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"><line x1=\"9\" y1=\"18\" x2=\"15\" y2=\"18\"><\/line><line x1=\"10\" y1=\"22\" x2=\"14\" y2=\"22\"><\/line><path d=\"M15.09 14c.18-.98.65-1.74 1.41-2.5A4.65 4.65 0 0 0 18 8 6 6 0 0 0 6 8c0 1 .23 2.23 1.5 3.5A4.61 4.61 0 0 1 8.91 14\"><\/path><\/svg>\n From the field\n <\/div>\n <p class=\"infobox__text\">In our experience, <strong>three out of four failures<\/strong> in technopolymers have a thermal root: underestimated temperature, insufficient clearance or absent lubrication. Before hypothesizing mechanical causes, always verify these three variables.<\/p>\n<\/div>\n<div class=\"infobox\">\n <div class=\"infobox__title\">\n <svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"14\" height=\"14\" viewBox=\"0 0 24 24\" fill=\"none\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"><path d=\"M4 4h16c1.1 0 2 .9 2 2v12c0 1.1-.9 2-2 2H4c-1.1 0-2-.9-2-2V6c0-1.1.9-2 2-2z\"><\/path><polyline points=\"22,6 12,13 2,6\"><\/polyline><\/svg>\n Ask us\n <\/div>\n <p class=\"infobox__text\">If you have a damaged gear and can’t trace the damage to one of the categories described, <a href=\"https:\/\/shop.stagnoligears.com\/en\/contacts\/\" target=\"_blank\" rel=\"noopener\" class=\"cta-link\">send<\/a> a photo to the technical office. We analyze the damage picture and indicate the most probable cause and the corrective action.<\/p>\n<\/div>\n\n <\/div>\n <\/div>\n <\/div>\n\n\n<script>\n (function () {\n var hideTimers = {};\n function positionTooltip(trigger, tooltip) {\n var margin = 8;\n tooltip.style.visibility = 'hidden';\n tooltip.style.top = '-9999px';\n tooltip.style.left = '-9999px';\n tooltip.removeAttribute('hidden');\n var ttRect = tooltip.getBoundingClientRect();\n var trRect = trigger.getBoundingClientRect();\n var vw = window.innerWidth, vh = window.innerHeight;\n var top = trRect.bottom + margin;\n var left = trRect.left;\n if (top + ttRect.height + margin > vh) {\n var above = trRect.top - ttRect.height - margin;\n top = above >= margin ? above : Math.max(margin, vh - ttRect.height - margin);\n }\n if (left + ttRect.width + margin > vw) left = vw - ttRect.width - margin;\n if (left < margin) left = margin;\n tooltip.style.top = top + 'px';\n tooltip.style.left = left + 'px';\n 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{"id":25623,"date":"2026-06-30T14:29:12","date_gmt":"2026-06-30T12:29:12","guid":{"rendered":"https:\/\/shop.stagnoligears.com\/?post_type=centro-tecnico&p=25623"},"modified":"2026-07-10T13:51:27","modified_gmt":"2026-07-10T11:51:27","slug":"failure-diagnostics-reading-the-damage-on-a-gear","status":"publish","type":"centro-tecnico","link":"https:\/\/shop.stagnoligears.com\/en\/technical-hub\/failure-diagnostics-reading-the-damage-on-a-gear\/","title":{"rendered":"Failure diagnostics: reading the damage on a gear"},"content":{"rendered":"\n\n \n \n \n Failure diagnostics: reading the damage on a gear<\/title>\n\n <link rel=\"preconnect\" href=\"https:\/\/fonts.googleapis.com\">\n <link rel=\"preconnect\" href=\"https:\/\/fonts.gstatic.com\" crossorigin=\"\">\n <link href=\"https:\/\/fonts.googleapis.com\/css2?family=Inter:wght@400;500;600;700&display=swap\" rel=\"stylesheet\">\n\n <style>\n *, *::before, *::after { box-sizing: border-box; margin: 0; padding: 0; }\n\n :root {\n --green: #1a6b3c;\n --green-dark: #0f4a28;\n --green-mid: #2d8a55;\n --green-light: #e8f4ed;\n --green-xlight: #f2faf5;\n --amber: #b45309;\n --amber-light: #fef3c7;\n\n --bg: #ffffff;\n --bg-soft: #f8f9fa;\n --bg-muted: #f1f3f5;\n --border: #e5e7eb;\n --border-mid: #d1d5db;\n\n --text-primary: #111827;\n --text-secondary: #4b5563;\n --text-muted: #9ca3af;\n\n --radius-sm: 6px;\n --radius-md: 8px;\n --radius-lg: 12px;\n --shadow-sm: 0 1px 3px rgba(0,0,0,.06), 0 1px 2px rgba(0,0,0,.04);\n --shadow-md: 0 4px 12px rgba(0,0,0,.08), 0 2px 4px rgba(0,0,0,.04);\n }\n\n body { min-height: 100vh; 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}\n\n .badge {\n display: inline-block;\n font-size: 12px;\n font-weight: 600;\n padding: 2px 8px;\n border-radius: 20px;\n background: var(--green-light);\n color: var(--green-dark);\n }\n\n \/* ============================================================\n RESPONSIVE\n ============================================================ *\/\n @media (max-width: 900px) {\n .article-body { flex-direction: column; padding: 20px 20px 48px; }\n }\n \n \/* Glossary tooltips *\/\n .glossary-term {\n border-bottom: 1px dotted var(--green);\n color: var(--green);\n font-style: italic;\n cursor: help;\n }\n .glossary-tooltip {\n position: fixed;\n z-index: 9999;\n background: #fff;\n border: 1px solid var(--border-mid);\n border-radius: var(--radius-md);\n box-shadow: var(--shadow-md);\n padding: 10px 14px;\n max-width: 300px;\n font-family: 'Inter', sans-serif;\n font-size: 13px;\n }\n .glossary-tooltip__title {\n font-weight: 600;\n color: var(--text-primary);\n margin-bottom: 4px;\n }\n .glossary-tooltip__def {\n font-size: 12.5px;\n color: var(--text-secondary);\n line-height: 1.6;\n }\n .glossary-tooltip__tag {\n display: inline-block;\n margin-top: 6px;\n font-size: 9px;\n font-weight: 600;\n padding: 2px 7px;\n border-radius: 20px;\n background: var(--green-light);\n color: var(--green-dark);\n text-transform: uppercase;\n letter-spacing: 0.04em;\n }\n\n <\/style>\n<\/head>\n<body>\n\n<div id=\"tt-gioco-di-flanchi-backlash\" class=\"glossary-tooltip\" hidden=\"\">\n <div class=\"glossary-tooltip__title\">Backlash<\/div>\n <div class=\"glossary-tooltip__def\">Free clearance between the flanks of two mating teeth, measured at the pitch circle. It prevents jamming due to thermal expansion or assembly errors.<\/div>\n <span class=\"glossary-tooltip__tag\">Glossary<\/span>\n<\/div>\n<div id=\"tt-pitting\" class=\"glossary-tooltip\" hidden=\"\">\n <div class=\"glossary-tooltip__title\">Pitting<\/div>\n <div class=\"glossary-tooltip__def\">Form of surface wear caused by contact fatigue. It manifests as micro-craters on tooth flanks resulting from cyclic Hertzian contact stress.<\/div>\n <span class=\"glossary-tooltip__tag\">Glossary<\/span>\n<\/div>\n<div id=\"tt-scuffing\" class=\"glossary-tooltip\" hidden=\"\">\n <div class=\"glossary-tooltip__title\">Scuffing<\/div>\n <div class=\"glossary-tooltip__def\">Damage caused by localised adhesion between tooth flanks following breakdown of the lubricant film. It occurs at high speeds and under heavy loads.<\/div>\n <span class=\"glossary-tooltip__tag\">Glossary<\/span>\n<\/div>\n\n <div class=\"article-page\">\n <div class=\"article-body\">\n <div class=\"article-body__main\"><script type=\"application\/ld+json\">\n{\n \"@context\": \"https:\/\/schema.org\",\n \"@graph\": [\n {\n \"@type\": \"TechArticle\",\n \"@id\": \"#article\",\n \"headline\": \"Failure diagnostics: reading the damage on a gear\",\n \"description\": \"A technopolymer gear doesn't break in silence. 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Before the final failure, the teeth already tell what’s going wrong: a few minutes of visual inspection are enough to read the cause and know what to correct.<\/p>\n\n<figure class=\"article__figure\">\n <img src=https:\/\/shop.stagnoligears.com\/wp-content\/uploads\/rottura-dente-ingranaggio.webp alt=\"Gear tooth root fracture\" \/>\n <figcaption>Gear tooth root fracture<\/figcaption>\n<\/figure>\n\n<h2 class=\"article__h2\" id=\"why-do-diagnostics\">\n <span class=\"article__h2-icon\"><svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"16\" height=\"16\" viewBox=\"0 0 24 24\" fill=\"none\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"><circle cx=\"11\" cy=\"11\" r=\"8\"><\/circle><line x1=\"21\" y1=\"21\" x2=\"16.65\" y2=\"16.65\"><\/line><\/svg><\/span>\n Why do diagnostics\n<\/h2>\n<p class=\"article__p\">When a gear breaks, the natural reaction is to replace it. But doing so without analyzing the type of damage means almost certainly seeing the problem reappear after a few hundred hours. Each damage picture corresponds to a specific cause and a precise corrective action.<\/p>\n\n<figure class=\"article__figure\">\n <img src=https:\/\/shop.stagnoligears.com\/wp-content\/uploads\/rottura-dente.webp alt=\"Primary gear tooth failure modes\" \/>\n <figcaption>Microscopic analysis of the primary gear tooth failure modes<\/figcaption>\n<\/figure>\n\n<h2 class=\"article__h2\" id=\"pitting-surface-fatigue\">\n <span class=\"article__h2-icon\"><svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"16\" height=\"16\" viewBox=\"0 0 24 24\" fill=\"none\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"><path d=\"M6 18h8\"><\/path><path d=\"M3 22h18\"><\/path><path d=\"M14 22a7 7 0 1 0 0-14h-1\"><\/path><path d=\"M9 14h2\"><\/path><path d=\"M9 12a2 2 0 0 1-2-2V6h6v4a2 2 0 0 1-2 2Z\"><\/path><path d=\"M12 6V3a1 1 0 0 0-1-1H9a1 1 0 0 0-1 1v3\"><\/path><\/svg><\/span>\n Pitting: surface fatigue\n<\/h2>\n<p class=\"article__p\">Appearance: small <strong>craters or pockmarks<\/strong> on the tooth flank, particularly in the zone of the pitch line. The surface looks pitted, as if struck by a punch at several points.<\/p>\n<p class=\"article__p\">Diagnosis: surface fatigue of the material. The micro-cracks form below the surface due to the repeated cycles of contact pressure, and propagate until small fragments of material detach. It’s a phenomenon of progressive degradation.<\/p>\n<p class=\"article__p\">Probable cause: excessive load, with contact pressure exceeding the material’s fatigue limit, or service life exceeded. The gear has worked beyond the design number of cycles.<\/p>\n<p class=\"article__p\">Action: reduce the load, increase the module, evaluate a higher-strength material such as <strong>PA6 reinforced with 30% glass fiber (PA6+30%GF)<\/strong>, or plan periodic replacement as a consumable component.<\/p>\n<h2 class=\"article__h2\" id=\"scuffing-localized-melting\">\n <span class=\"article__h2-icon\"><svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"16\" height=\"16\" viewBox=\"0 0 24 24\" fill=\"none\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"><path d=\"M8.5 14.5A2.5 2.5 0 0 0 11 12c0-1.38-.5-2-1-3-1.072-2.143-.224-4.054 2-6 .5 2.5 2 4.9 4 6.5 2 1.6 3 3.5 3 5.5a7 7 0 1 1-14 0c0-1.153.433-2.294 1-3a2.5 2.5 0 0 0 2.5 3z\"><\/path><\/svg><\/span>\n Scuffing: localized melting\n<\/h2>\n<p class=\"article__p\">Appearance: <strong>streaks parallel<\/strong> to the sliding direction, often with patchy dark or shiny zones. The surface looks smeared or dirtied. In technopolymers it’s common to find residues of melted material in the cavities between teeth.<\/p>\n<p class=\"article__p\">Diagnosis: localized surface melting. The temperature in the contact zone has exceeded the softening temperature of the polymer, melting it locally.<\/p>\n<p class=\"article__p\">Probable cause: excessive operating temperature, insufficient flank <dfn id=\"def-gioco-di-flanchi-backlash\"><span class=\"glossary-term\" data-tooltip=\"tt-gioco-di-flanchi-backlash\" title=\"Free clearance between the flanks of two mating teeth, measured at the pitch circle. It prevents jamming due to thermal expansion or assembly errors.\">backlash<\/span><\/dfn> up to seizing, absent or inadequate lubrication.<\/p>\n<p class=\"article__p\">Action: verify the backlash, check the ambient and operating temperature, evaluate a hybrid pairing (technopolymer-metal or with thermal additives) to improve heat dissipation.<\/p>\n<h2 class=\"article__h2\" id=\"root-fracture\">\n <span class=\"article__h2-icon\"><svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"16\" height=\"16\" viewBox=\"0 0 24 24\" fill=\"none\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"><path d=\"M10.29 3.86L1.82 18a2 2 0 0 0 1.71 3h16.94a2 2 0 0 0 1.71-3L13.71 3.86a2 2 0 0 0-3.42 0z\"><\/path><line x1=\"12\" y1=\"9\" x2=\"12\" y2=\"13\"><\/line><line x1=\"12\" y1=\"17\" x2=\"12.01\" y2=\"17\"><\/line><\/svg><\/span>\n Root fracture\n<\/h2>\n<p class=\"article__p\">Appearance: the tooth is <strong>completely detached<\/strong> from the gear wheel, with a fracture surface at the base.<\/p>\n<p class=\"article__p\">Diagnosis: exceeding the yield limit in bending.<\/p>\n<p class=\"article__p\">Probable cause: a sudden load peak or shock not foreseen at the design stage.<\/p>\n<p class=\"article__p\">Action: verify whether the application presents impulsive loads not considered in the sizing. Evaluate a material with greater resilience or a more robust tooth profile.<\/p>\n<h2 class=\"article__h2\" id=\"plastic-deformation\">\n <span class=\"article__h2-icon\"><svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"16\" height=\"16\" viewBox=\"0 0 24 24\" fill=\"none\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"><line x1=\"18\" y1=\"20\" x2=\"18\" y2=\"10\"><\/line><line x1=\"12\" y1=\"20\" x2=\"12\" y2=\"4\"><\/line><line x1=\"6\" y1=\"20\" x2=\"6\" y2=\"14\"><\/line><\/svg><\/span>\n Plastic deformation\n<\/h2>\n<p class=\"article__p\">Appearance: the teeth are <strong>visibly deformed<\/strong>, bent or with a distorted profile, but not broken.<\/p>\n<p class=\"article__p\">Diagnosis: exceeding the softening temperature under continued load.<\/p>\n<p class=\"article__p\">Probable cause: excessive friction from insufficient clearance or wrong lubrication, or ambient temperature higher than foreseen at the design stage.<\/p>\n<p class=\"article__p\">Action: verify the HDT (Heat Deflection Temperature, the temperature at which the material begins to deform under load) relative to the real operating temperature. Recalculate the minimum clearance.<\/p>\n<h2 class=\"article__h2\" id=\"diagnostic-table\">\n <span class=\"article__h2-icon\"><svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"16\" height=\"16\" viewBox=\"0 0 24 24\" fill=\"none\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"><circle cx=\"12\" cy=\"12\" r=\"10\"><\/circle><\/svg><\/span>\n Diagnostic table\n<\/h2>\n<div class=\"article__table-wrap\">\n<table class=\"article__table\">\n<thead><tr><th>Visible sign<\/th><th>Technical diagnosis<\/th><th>Probable cause<\/th><\/tr><\/thead>\n<tbody><tr><td><dfn id=\"def-pitting\"><span class=\"glossary-term\" data-tooltip=\"tt-pitting\" title=\"Form of surface wear caused by contact fatigue. It manifests as micro-craters on tooth flanks resulting from cyclic Hertzian contact stress.\">Pitting<\/span><\/dfn><\/td><td>Surface fatigue of the material<\/td><td>Excessive load or exceeded life cycles<\/td><\/tr>\n<tr><td><dfn id=\"def-scuffing\"><span class=\"glossary-term\" data-tooltip=\"tt-scuffing\" title=\"Damage caused by localised adhesion between tooth flanks following breakdown of the lubricant film. It occurs at high speeds and under heavy loads.\">Scuffing<\/span><\/dfn><\/td><td>Localized surface melting<\/td><td>Excessive temperature or lack of clearance<\/td><\/tr>\n<tr><td>Root fracture<\/td><td>Exceeding the yield limit<\/td><td>Sudden load peak or shock<\/td><\/tr>\n<tr><td>Plastic deformation<\/td><td>Exceeding the softening temperature<\/td><td>Excessive friction or environment too hot<\/td><\/tr><\/tbody>\n<\/table>\n<\/div>\n<div class=\"infobox infobox--grey\">\n <div class=\"infobox__title\">\n <svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"14\" height=\"14\" viewBox=\"0 0 24 24\" fill=\"none\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"><line x1=\"9\" y1=\"18\" x2=\"15\" y2=\"18\"><\/line><line x1=\"10\" y1=\"22\" x2=\"14\" y2=\"22\"><\/line><path d=\"M15.09 14c.18-.98.65-1.74 1.41-2.5A4.65 4.65 0 0 0 18 8 6 6 0 0 0 6 8c0 1 .23 2.23 1.5 3.5A4.61 4.61 0 0 1 8.91 14\"><\/path><\/svg>\n From the field\n <\/div>\n <p class=\"infobox__text\">In our experience, <strong>three out of four failures<\/strong> in technopolymers have a thermal root: underestimated temperature, insufficient clearance or absent lubrication. Before hypothesizing mechanical causes, always verify these three variables.<\/p>\n<\/div>\n<div class=\"infobox\">\n <div class=\"infobox__title\">\n <svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"14\" height=\"14\" viewBox=\"0 0 24 24\" fill=\"none\" stroke=\"currentColor\" stroke-width=\"2\" stroke-linecap=\"round\" stroke-linejoin=\"round\"><path d=\"M4 4h16c1.1 0 2 .9 2 2v12c0 1.1-.9 2-2 2H4c-1.1 0-2-.9-2-2V6c0-1.1.9-2 2-2z\"><\/path><polyline points=\"22,6 12,13 2,6\"><\/polyline><\/svg>\n Ask us\n <\/div>\n <p class=\"infobox__text\">If you have a damaged gear and can’t trace the damage to one of the categories described, <a href=\"https:\/\/shop.stagnoligears.com\/en\/contacts\/\" target=\"_blank\" rel=\"noopener\" class=\"cta-link\">send<\/a> a photo to the technical office. We analyze the damage picture and indicate the most probable cause and the corrective action.<\/p>\n<\/div>\n\n <\/div>\n <\/div>\n <\/div>\n\n\n<script>\n (function () {\n var hideTimers = {};\n function positionTooltip(trigger, tooltip) {\n var margin = 8;\n tooltip.style.visibility = 'hidden';\n tooltip.style.top = '-9999px';\n tooltip.style.left = '-9999px';\n tooltip.removeAttribute('hidden');\n var ttRect = tooltip.getBoundingClientRect();\n var trRect = trigger.getBoundingClientRect();\n var vw = window.innerWidth, vh = window.innerHeight;\n var top = trRect.bottom + margin;\n var left = trRect.left;\n if (top + ttRect.height + margin > vh) {\n var above = trRect.top - ttRect.height - margin;\n top = above >= margin ? above : Math.max(margin, vh - ttRect.height - margin);\n }\n if (left + ttRect.width + margin > vw) left = vw - ttRect.width - margin;\n if (left < margin) left = margin;\n tooltip.style.top = top + 'px';\n tooltip.style.left = left + 'px';\n tooltip.style.visibility = '';\n }\n function showTooltip(ttId, trigger) {\n if (hideTimers[ttId]) { clearTimeout(hideTimers[ttId]); hideTimers[ttId] = null; }\n positionTooltip(trigger, document.getElementById(ttId));\n }\n function hideTooltip(ttId) {\n hideTimers[ttId] = setTimeout(function () {\n var tt = document.getElementById(ttId);\n if (tt) tt.setAttribute('hidden', '');\n hideTimers[ttId] = null;\n }, 180);\n }\n function cancelHide(ttId) {\n if (hideTimers[ttId]) { clearTimeout(hideTimers[ttId]); hideTimers[ttId] = null; }\n }\n document.querySelectorAll('[data-tooltip]').forEach(function (trigger) {\n var ttId = trigger.getAttribute('data-tooltip');\n trigger.addEventListener('mouseenter', function () { showTooltip(ttId, trigger); });\n trigger.addEventListener('mouseleave', function () { hideTooltip(ttId); });\n });\n ['tt-gioco-di-flanchi-backlash', 'tt-pitting', 'tt-scuffing'].forEach(function (ttId) {\n var tt = document.getElementById(ttId);\n if (!tt) return;\n 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