Gear Shaft Inspection : Gear shafts are critical components in machinery, transmitting torque and rotation. Proper inspection ensures reliability, longevity, and performance. Below is a step-by-step guide for inspecting gear shafts.

1.Visual Inspection

Surface Defects: Check for cracks, pitting, scoring, or corrosion.

Wear Patterns: Look for uneven wear, scuffing, or signs of fatigue.

Keyway & Splines: Inspect for deformation, burrs, or excessive wear.

Lubrication Condition: Ensure proper lubrication; check for contamination.

2.Dimensional Inspection

Verify critical dimensions against drawings:

Shaft Diameter (micrometer, caliper)

Runout (dial indicator) – Check for bending or misalignment.

Gear Tooth Profile (gear tooth caliper, CMM) – Verify module, pressure angle, and tooth thickness.

Keyway/Spline Dimensions (go/no-go gauges)

Tools: Micrometer, caliper, dial indicator, CMM (Coordinate Measuring Machine).

3. Hardness & Material Integrity

Rockwell Hardness Test: Ensure proper heat treatment.

4.Runout & Alignment Check

Radial Runout: Place a dial indicator on the shaft and rotate to measure deviation.

Axial Runout: Check for wobble at the shaft end.

Gear Mesh Alignment: Use backlash measurement tools to ensure proper engagement.

Tools: Dial indicator, alignment laser (for precision checks).

5. Bearing & Journal Inspection

Bearing Fit: Check for looseness or excessive tightness.

Journal Wear: Measure diameter and surface finish (Ra value).

Bearing Seats: Inspect for fretting or brinelling.

Tools: Bore gauge, surface roughness tester.

6.Documentation & Reporting

Record all measurements and compare with OEM specifications.