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Originally Posted by michchinn
Will using a steel 20t gear in the 3rd stage accelerate wear on the aluminum 64t gear that it meshes with in the third stage?
Thank you all for your help and suggestions.
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Yes, but if you properly lubricate your gears they will not wear significantly within the runtime of an FRC robot, and this will not compromise performance. Aluminum gears like to wear a little until they run nicely and then that tapers off for a bit.
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However, I would advise you to not use aluminum gears unless you are right up against the weight limit or are using very large gears (team 25, I am looking at you with those massive gears on your wheels...) Steel has better wear and fatigue properties in general.
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There is nothing wrong with using aluminum gears in FRC - the weight savings is dramatic and for most applications the strength is just fine. The aluminum gears Vex produces are of higher quality than steel gears from AndyMark as well - better tooth profile, more consistent manufacturing, etc. Wear and fatigue properties are not really a concern with 100-200 hour run times.