Lecture 15 – WORM GEARS

Contents

1. Worm gears –an introduction

2. Worm gears - geometry and nomenclature
3. Worm gears- tooth force analysis
4. Worm gears-bending stress analysis
5. Worm gears-permissible bending stress
6. Worm gears- contact stress analysis
7. Worm gears- permissible contact stress
8. Worm gears -Thermal analysis

WORM GEARS – INTRODUCTION

Worm gears are used for transmitting power between two non-parallel, non-intersecting shafts.
High gear ratios of 200:1 can be got.

Fig.1. Single enveloping Fig. 2. Double enveloping

worm gear. worm gear.
Fig.3 showing the cut section of a worm gearbox with Fins and fan for cooling.

WORM GEARS – GEOMETRY AND NOMENCLATURE

a. The geometry of a worm is similar to that of a power screw. Rotation of the worm
simulates a linearly advancing involute rack, Fig.4.
b. The geometry of a worm gear is similar to that of a helical gear, except that the teeth are
curved to envelop the worm.
c. Enveloping the gear gives a greater area of contact but requires extremely precise
mounting.

1. As with a spur or helical gear, the pitch diameter of a worm gear is related to its circular
pitch and number of teeth Z by the formula
Z 2p
d2 = (1)
π
2. When the angle is 90° between the nonintersecting shafts, the worm lead angle λ is
equal to the gear helix angle ψ. Angles λ and ψ have the same hand.

3. The pitch diameter of a worm is not a function of its number of threads, Z1.

4. This means that the velocity ratio of a worm gear set is determined by the ratio of
gear teeth to worm threads; it is not equal to the ratio of gear and worm diameters.
ω1 Z 2
= (2)
ω 2 Z1
5. Worm gears usually have at least 24 teeth, and the number of gear teeth plus worm
threads should be more than 40:
Z1 + Z2 > 40 (3)
6. A worm of any pitch diameter can be made with any number of threads and any
axial pitch.
7. For maximum power transmitting capacity, the pitch diameter of the worm should
normally be related to the shaft center distance by the following equation

C0.875 C0.875
≤ d1 ≤ (4)
3.0 1.7

8. Integral worms cut directly on the shaft can, of course, have a smaller diameter than
that of shell worms, which are made separately.
9. Shell worms are bored to slip over the shaft and are driven by splines, key, or pin.
10. Strength considerations seldom permit a shell worm to have a pitch diameter less
than d1 = 2.4p + 1.1 (5)
11. The face width of the gear should not exceed half the worm outside diameter.
b ≤ 0.5 da1 (6)
 12. Lead angle λ, Lead L, and worm pitch diameter d1 have the following relation-ship in
connection with the screw threads.
L
tan λ = (7)
πd1

13. To avoid interference, pressure angles are commonly related to the worm lead angle
as indicated in Table 1.

Table 1. Maximum Worm Lead Angle and Worm Gear Lewis Form Factor for Various Pressure
angles.

Pressure Maximum Lewis form Modified

Angle Φn Lead Angle λ factor y Lewis form
(Degrees) (degrees) factor Y

14.5 15 0.100 0.314

20 25 0.125 0.393

25 35 0.150 0.473

30 45 0.175 0.550

Table 2. Frequently used standard values of module and axial pitch of worm or circular pitch of
gear p in mm :

Module m mm 2.0 2.5 3.15 4.0 5.0 6.3

Axial pitch p mm 6.283 7.854 9.896 12.566 15.708 19.792

Module m mm 8 10 12.5 16 20

Axial pitch p mm 25.133 31.416 39.270 50.625 62.832

b. Values of addendum and tooth depth often conform generally to helical gear practice but they
may be strongly influenced by manufacturing considerations.
c. The load capacity and durability of worm gears can be significantly increased by
modifying the design to give predominantly “recess action” i.e. the angle of approach
would be made small or zero and the angle of recess larger.

WORM GEARS – FORCE ANALYSIS

a. The tangential, axial, and radial force components acting on a worm and gear are
illustrated in Fig.5 .

b. For the usual 90° shaft angle, the worm tangential force is equal to the gear axial
force and vice versa,
F1t = F2a ( 8 )
F2t = F1a ( 9 )
c. The worm and gear radial or separating forces are also equal,
F1r = F2r (10)

If the power and speed of either the input or output are known, the tangential force acting on this
member can be found from equation

1000 W
F1t = (11)
V
 1. In the following figure, the driving member is a clockwise-rotating right hand worm.
2. The force directions shown can readily be visualized by thinking of the worm as a
right hand screw being turned so as to pull the “nut” (worm gear tooth) toward the
“screw head”.
3. Force directions for other combinations of worm hand and direction of rotation can
be similarly visualized.

WORM GEARS – THRUST FORCE ANALYSIS, FIG.6.

WORM GEARS – THRUST FORCE ANALYSIS , FIG. 7.

The thread angle λ of a screw thread corresponds to the pressure angle φn of the worm, we can
apply the force, efficiency, and self-locking equations of power screw directly to a worm and
gear set.
These equations are derived below with reference to the worm and gear geometry.
Figs. 8 to 10 show in detail the forces acting on the gear. Components of the normal tooth force
are shown solid. Components of the friction force are shown with the dashed lines.
Fig.10 illustrates the same directions of rotation as figure a but with the torque direction reversed
(i.e., gear driving). Then contact shifts to the other side of the gear tooth, and the normal load
reverses.

The friction force is always directed to oppose the sliding motion. The driving worm is rotating
clockwise:

F2t =F1a =Fncosφncosλ-f Fnsinλ (11)

F1t =F2a =Fncosφnsinλ+f Fncosλ (12)

F2r =F1r =Fnsinφn (13)

Combining eqns. (11) with (12), we have:
F
2t = cosφn cosλ - f sinλ (14)
F cosφn sinλ + f cosλ
1t
Combining eqns. (11) with (13) and (12) with (13), we have:
 sinφn
F2r =F1r =F2t
cosφn cosλ - f sinλ
sinφn
=F1t (15)
cosφn sinλ + f cosλ

WORM GEARS – KINEMATICS

The relationship between worm tangential velocity, gear tangential velocity, and sliding velocity.
V2
= tanλ (16)
V1

WORM GEARS– EFFICIENCY

Efficiency η is the ratio of work out to work in. For the usual case of the worm serving as input
member,
F V cos φn cos λ - f sin λ
η = 2t 2t = tan λ
F V cos φn sin λ + f cos λ
1t 1
cos φn - f tan λ
η= (17)
cos φn + f cot λ

The overall efficiency of a worm gear is a little lower because of friction losses in the bearings
and shaft seals, and because of “churning” of the lubricating oil.

WORM GEARS– FRICTION ANALYSIS

The coefficient of friction, f, varies widely depending on variables such as the gear materials,
lubricant, temperature, surface finishes, accuracy of mounting, and sliding velocity. The typical
coefficient of friction of well lubricated worm gears are given in Fig.11.
WORM GEARS – KINEMATICS

The sliding velocity Vs is related to the worm and gear pitch line velocities and to the worm lead
angle by

V1 V2
Vs = = (18)
cosλ sinλ

WORM GEARS – FRICTION FORCE ANALYSIS

a. Eqn. 18 shows that with a sufficiently high Coefficient of friction, the gear tangential
force becomes zero, and the gearset “self-locks” or does not “over-haul.”
F1t = Fn cos φn sin λ - f Fn cos λ (19)
b. With this condition, no amount of worm torque can produce motion.
c. Self-locking occurs, if at all, with the gear driving.
d. This is desirable in many cases and helps in holding the load from reversing, similar to a self-
locking power screw.

The worm gear set self-locks if this force goes to zero, which happens if

f ≥ cosφn tanλ (20)

A worm gear set can be always overhauling or never overhauling, depending on the selected
value coefficient of friction (i.e., λ and to a lesser extent on φn).
WORM GEARS – BENDING AND SURFACE FATIGUE STRENGTHS

Worm gear capacity is often limited not by fatigue strength but by cooling capacity. The total
gear tooth load Fd is the product of nominal load Ft and factors accounting for impact from tooth
inaccuracies and deflections, misalignment, etc.). Fd must be less than the strength the bending
fatigue and surface fatigue strengths Fb and Fw

The total tooth load is called the dynamic load Fd, the bending fatigue limiting load is called
strength capacity Fb, and the surface fatigue limiting load is called the wear capacity Fw. For
satisfactory performance,
Fb ≥ Fd (21) and Fw ≥ Fd (22)

The “dynamic load” is estimated by multiplying the nominal value of gear tangential force by
velocity factor “Kv” given in the following figure.

⎛ 6.1+ V2 ⎞
Fd =F2t K v =F2t ⎜ ⎟ (23)
⎝ 6.1 ⎠
Adapting the Lewis equation to the gear teeth, we have
Fb =[σb ] bpy = [σb ] bmY (24)

Where, [σb] is the permissible bending stress in bending fatigue, in MPa, Table 3

Table 3. Permissible stress in bending fatigue, in MPa

Material of the gear [σb] MPa

Centrifugally cast 23.5

Cu-Sn bronze

Aluminium alloys 11.3

Al-Si alloy

Zn alloy 7.5

Cast iron 11.8

b – is the face width in mm ≤ 0.5 da1

p – is the axial pitch in mm, Table 2
m – is module in mm, Table 2
y – is the Lewis form factor, Table 1
Y – is modified Lewis form factor, Table 1
By assuming the presence of an adequate supply of appropriate lubricant, the following equation
suggested by Buckingham may be used for wear strength calculations

Fw =d2 bK w (25)
Fw – Maximum allowable value of dynamic load with respect to surface fatigue.
dg - Pitch diameter of the gear.
b - Face width of the gear.
Kw - A material and geometry factor with values empirically determined from the Table 4.

Table 4. Worm Gear Wear Factors Kw

Material Kw (MPa)

Worm Gear λ<10° λ<25° λ>25°

Steel, 250 BHN Bronze 0.414 0.518 0.621

Hardened steel Bronze 0.552 0.690 0.828

(Surface 500 BHN)
Chill-cast 0.828 1.036 1.243
Bronze

Cast iron Bronze 1.036 1.277 1.553

WORM GEARS –THERMAL CAPACITY

The continuous rated capacity of a worm gear set is often limited by the ability of the housing to
dissipate friction heat without developing excessive gear and lubricant temperatures. Normally,
oil temperature must not exceed about 200ºF (93oC) for satisfactory operation.

The fundamental relationship between temperature rise and rate of heat dissipation used for
journal bearings, does hold good for worm gearbox.
H = CH A ( T0 -Ta ) (26)
Where
H – Time rate of heat dissipation (Nm/sec)
CH – Heat transfer coefficient (Nm/sec/m2/ºC)
A – Housing external surface area (m2)
To – Oil temperature (º C)
Ta – Ambient air temperature (º C)
Surface area of A for conventional housing designs may be roughly estimated from the Equation:
A =14.75 C1.7 (27)

Where A is in m2 and C (the distance between the shafts) is in m.

Housing surface area can be made far greater than the above equation value by incorporating
cooling fins. Rough estimates of C can be taken from the following figure.

WORM GEARS–DESIGN GUIDELINES

Table 5. Recommended pressure angles and tooth depths for worm gearing

Lead angle λ Pressure angle φn Addendum Dedendum

in degrees in degrees ha in mm hf in mm

0-15 14.5 0.3683 p 0.3683 p

15-30 20 0.3683 p 0.3683 p

30-35 25 0.2865 p 0.331 p

35-40 25 0.2546 p 0.2947 p

40-45 30 0.2228 p 0.2578 p

Table 6. Efficiency of worm gear set for f = 0.05

Helix angle Efficiency Helix angle Efficiency Helix angle Efficiency

Ψ in O η in % Ψ in O η in % Ψ in O η in %

1.0 25.2 7.5 71.2 20.0 86.0

2.5 46.8 10.0 76.8 25.0 88.0

5.0 62.6 15.0 82.7 30.0 89.2

Table 7. Minimum number of teeth in the worm gear

Pressure angle φn 14.5o 17.5o 20o 22.5o 25o 27.5o 30o

Z2 minimum 40 27 21 17 14 12 10

Table 8. Maximum lead angle for normal pressure angle

Normal Pressure angle φn 14.5o 20o 25o 30o

Maximum lead angle λmax 16 o 25 o 35 o 45 o