Rapid wear rate: Due to factors such as the machining, assembly, and adjustment of new machine components, friction surfaces are rough, the contact area between mating surfaces is small, and surface pressure distribution is uneven. During operation, the high and low points on component surfaces interlock and rub against each other; the resulting metal debris acts as an abrasive, further accelerating wear on the mating surfaces. Consequently, components-especially mating surfaces-are prone to rapid wear during the break-in period. Operating under overload conditions at this stage can lead to component damage and premature failure.
Poor lubrication: Because the mating clearances of newly assembled components are tight, and achieving uniform clearance is difficult due to assembly factors, it is hard for lubricating oil or grease to form a uniform film on friction surfaces to prevent wear. This reduces lubrication efficiency, leading to premature, abnormal wear of components. In severe cases, precision mating surfaces may become scratched or seize, resulting in equipment failure.
Loosening: Newly machined and assembled components often have deviations in geometric shape and mating dimensions. During the initial period of use, factors such as alternating loads (impact and vibration), thermal expansion, deformation, and rapid wear can cause previously tightened components to loosen.
Leakage: Loosening of components, vibration, and thermal effects can cause leakage at sealing surfaces and pipe joints. Certain casting or machining defects may be difficult to detect during assembly and testing but become apparent under the vibration and impact of actual operation-manifesting as oil or water leaks. Therefore, leakage is common during the break-in period.
Operational errors: Due to insufficient understanding of the machine's structure and performance-particularly among new operators-operational errors frequently occur, potentially leading to equipment malfunctions or even serious mechanical accidents.
