Machine Design II Prof. K.Gopinath & Prof. M.M.

Mayuram

Module 2- GEARS

Lecture 16 – WORM GEARS WORKED OUT PROBLEMS

Contents

16.1. Worm gears – force analysis problem

16.2. Worm gears- design problem
16.3. Gearbox design procedure.

16.1 WORM GEARS- PROBLEM 1

A two tooth right hand worm transmits 2 kW at 2950 rpm to a 32 tooth worm gear. The
worm gear is of 4 mm module, 20o pressure and a face width of 30 mm. The worm is of
pitch diameter of 50 mm with a face width of 65 mm. The worm is made of steel case
carburized OQ and T and ground. The worm gear is made of phosphor bronze.
(a) Find the centre distance, the lead and the lead angle.
(b) Find the bearing reactions on the worm gear and worm shaft and the torque
output.
(c) Find the efficiency.

The general arrangement and isometric views are shown in Fig.16.1 and Fig.16.2.

Fig.1 General arrangement of the worm drive

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Fig.16.2 Isometric view of the worm gears in mesh

Data:

W = 2 kW, n 1 = 2950 rpm, Z 1 = 2, Z2 = 32, m = 4mm, φ = 20o, d 1 = 50 mm, b 1 = 65 mm,

b 2 = 28 mm. Pinion material case carburized steel and Gear material phosphor bronze.

Q – (a) C =?, L=?, λ = ?, Q-(b) bearing reactions? T 2 =? and Q (c) η = ?

Solution: (a)

d 2 = m Z 2 = 4 x 32 = 128 mm
Centre distance C= 0.5(d 1 + d 2 ) = 0.5(50+128) =79mm
Axial pitch: p = πm = 3.14x4 = 12.56 mm
Lead: L = p Z 1 = 12.56 x 2 = 25.12 mm
Lead angle: λ = tan-1( L / π d 1 ) = tan-1(25.12 /π x 50) = 9.09o

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Solution: (b)
V 1 = V m = (πd 1 n 1 /60000) = π x 50 x 2950 / 60000 = 7.72 m/s
n 2 = n 1 / i = {n 1 (Z 2 /Z 1 )} = 2950 / (32/2) = 184.38 rpm
V 2 = (πd 2 n 2 /60000) = πx128x184.38/60000 =1.24m/s
V S = V 1 /cos λ = 7.72 / cos9.09o = 7.82 m/s
For V S = 7.82 m/s and the given materials f = 0.024 from Fig.16.3.
Since the helix angle of the gear is the same as the lead angle of the worm,
Φ n = tan-1( tanφ 1 cos ψ) = tan-1(tan20o cos 9.09o) = 19.77o
F t1 = W / V 1 = 2000/ 7.72 = 259 N

Fig.16.3 Friction of well lubricated worm gears, A for cast iron worm and worm
gear and B for case hardened steel worm and phosphor bronze worm gear.

Ft
Fn 
cos φn sin λ  f cos λ
259
  1503N
cos19.77 sin9.09o  0.024 cos 9.09o
o

F r1 = Fy = F n sinφ n = 1503 sin19.77o = 508 N

F a1 = Fz = F n (cos φ n cosλ - f sin λ) = 1503 (cos 19.77o cos 9.09o - 0.024 sin 9.09o) =
1391 N

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Worm Gears – Force Analysis

Fig.16.4 Forces on the worm gear tooth on the pitch cylinder.

Referring to the Fig.16.4, we can now write down the forces acting on the worm gear
tooth.

F t2 = F a1 = 1391 N F r2

F a2 = F t1 = 259 N F a2

F r2 = F r1 = 508 N i.e., F t2

Fig.16.5 Sketch showing the forces acting on worm gear shaft

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Since Bearing B takes the entire thrust load,

 F B x = F a2 = 259 N

Taking moment about z axis through A, we get

F B y x 105 – F a2 x 64 – F r2 x 40 = 0
i.e., 105 F B y - 259 x 64 – 508 x 40 = 0
F B y = 351 N
∑ Fy = 0, from which F a y = 508-351 = 157 N

By taking moment about y axis through A, we have

F t2 x 40 – F B z x 105 = 0
i.e., 1391 x 40 – 105 F B z = 0
 F B z = 530 N
 ∑ Fz = 0 from which F A z = 1391 – 530 = 861 N

 T = F t2 x r 2 = 1391 x 64 x10-3 = 89.02 Nm

Fig.16.6 Sketch showing the calculated value of forces acting on worm gear shaft

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Fig.16.7 Forces acting on pinion shaft and bearing reactions.

Since the bearing at C takes the entire thrust,

F C z = F a1 = 1391 N.

Taking moment about y (vertical) axis through D,

F C x x 80 – F t1 x40 = 0, 80 F C x – 259x40 =0
 F c x = 129.5 N
 F D x = 129.5 N since ∑Fx = 0

Taking moment about x (horizontal) axis through D,

F c y x 80 – F a1 x 25 - F r1 x 40 = 0
80 F c y - 1391 x 25 – 508 x 40 = 0
 F C y = 689 N From ∑Fy = 0, F D y = -181 N

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Fig.16.8 Calculated values of forces acting on pinion shaft and bearing reactions.

Solution: (C) Efficiency of the gearbox

The efficiency of the gearbox is given by η

cos n - f tan 

cos n  f cot 

cos19.77o - 0.024 tan9.09o


cos19.77o  0.024 cot 9.09o

 0.859

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

16.2 WORM GEARS- PROBLEM 2

Design a worm gear set to deliver 12 kW from a shaft rotating at 1500 rpm to another
rotating at 75 rpm.

Solution:
20o normal pressure angle worm gear is assumed for which the lead angle should not
exceed 25o (Table 1) and Z 2 minimum is 21 (Table 2). Allowing 6o lead per thread of the
worm, the worm could have 4 or less teeth. Z 1 = 4 or quadruple threaded worm is
assumed

Table 16.1 Maximum Worm Lead Angle and Worm Gear Lewis Form Factor for
Various Pressure angles

Pressure Angle Maximum Lewis form Modified

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

From the worm gears–design guidelines we have,

Table 16.2 Minimum number of teeth in the worm gear

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

φn

Z 2 minimum 40 27 21 17 14 12 10

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

i = n 1 / n 2 = 1500 /75 = 20 = Z 2 / Z 1
ω 1 = 2πn 1 /60 = 2x3.14x1500 /60 =157 rad/s
Z 2 = i x Z 1 = 20 x 4 = 80
A centre distance of 250 mm (as per R10 series) is assumed.

C0.875 C0.875
 d1 
3.0 1.7

d 1 ≥C 0.875 /3 = 2500.875 /3 ≥ 42 mm and

d 1 ≤ C 0.875 /1.7=75 mm.
d 1 = 72 mm is taken.

Since d 1 ≈ 4p 2 or circular pitch,

p 2 = d 1 /4 = 72 / 4= 18 mm
m = p /π = 18/3.14 = 5.73 mm take standard module of 6mm.
Hence, d 2 = m Z 2 = 6 x 80 = 480 mm.
Actual centre distance: C = 0.5 (d 1 + d 2 )
= 0.5(72+480) = 276 mm.
Check for d 1 ≤ C 0.875/1.7 ≤ 80.4 mm, d 1 = 80 mm is taken.

C = 0.5(d 1 + d 2 ) = 0.5(80+480) = 280 mm

Lead = N tw x p a = 4 x 18.84 = 75.36 mm
tan λ = L / π d 1 = 75.36 / 3.14x72 = 0.3333
λ = 18.43o = ψ
ω 2 = (2πn 2 /60) = (2x3.14x75/60) = 7.85 rad/s
V 2 = ω 2 r 2 = 7.85 x (0.5 x 480) x 10-3 = 1.884 m/s
F t = 1000W/ V = 1000 x 12/ 1.884 = 6370 N
b ≤ 0.5 d a1 , b ≤ 0.5(d 1 + 2m) ≤ 0.5 x (80+2x6) ≤ 46
b = 45 mm is assumed.
Y = 0.393 from Table 1 for φ n = 20o

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Table 16.1 Maximum Worm Lead Angle and Worm Gear Lewis Form Factor for
Various Pressure angles which is reproduced below for convenience of selection.

Pressure Angle Φ n Maximum Lewis form Modified

(Degrees) Lead Angle λ factor y Lewis form
(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

 6.1+ V2   6.1+1.884 
Fd =F2t    6370x    8133N
 6.1   6.1 

Choosing phosphor bronze for the gear and heat treated C45 steel for the ground worm,

[σ b ] = 80 MPa from Table 16.3

Beam strength of the worm gear

Fb = [ b ] bmY = 80x45x6x0.393 = 8489 N

Worm gears – bending and surface fatigue strengths are given Table 16.3

Table 16.3 Permissible stress in bending fatigue

Material of the gear [σ b ] MPa

Centrifugally cast Cu-Sn bronze 23.5

Phosphor bronze 80

Aluminium alloys Al-Si 11.3

Zn Alloy 7.5

Cast iron 11.8

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

F b ( 8489) > F d ( 8133) Hence the design is safe from bending fatigue consideration.
Check for the wear strength.

Fw =d2 bK w  480x 45x 0.518  11189 N

K w = 0.518 for steel worm vs bronze worm gear with λ < 25o from Table 16.4.
F w (11189) > F d (8133), the design is safe from wear strength consideration.

Table 16.4 Worm Gear Wear Factors K w

Material K w (MPa)

Worm Gear <10 <25 >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

AGMA recommendation for the axial length of the Worm is, L w

Z2 80
L w  p a (4.5  )  18.84x(4.5  )  115mm
50 50

Worm Velocity V 1 = ω 1 r 1 = 157 x 0.04= 6.28 m/s

V1 6.28
Vs    6.62 m / s
cos λ cos18.43o

From the Fig. 16.9 worm gear friction characteristics, for V s = 6.62 m/s f = 0.025

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

Fig. 16.9 Friction of well lubricated worm gears, A for cast iron worm and gear
and B for case hardened steel worm and phosphor bronze worm gear

Ft2 6370
Fn    7145N
cosφn cos λ cos20 cos18.43o
o

cos n - f tan 

cos n  f cot 
cos 20o - 0.025 tan18.43o

cos 20o  0.025 cot 18.43o
 0.918

Heat generated during operation: H g = (1-η)W = (1-0.918)12000= 984 Nm

Surface area A for conventional housing designs may be roughly estimated from the
equation:

A =14.75 C1.7
Where A is in m2 and C (the distance between the shafts) is in m.

A =14.75 x0.281.7  1.694m2

Heat generated during operation: H g

From Fig. 16.10 the C H = 32 Nm/s/m2/oC for n 1 =1500rpm

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

H d = C H A (T o – T a ) assuming T a = 35oC
= 32 x 1.694x (T o – 35o) = 54.21 (T o – 35o)
H g = 984 Nm

T 0 = 53.2o C < 93o C permissible for oil.

Hence the design is OK from thermal considerations.

Fig.16.10 Influence of worm speed on heat transfer.

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

16.3 GEARBOX DESIGN

1. Design of gears is based on beam strength, pitting and scuffing (high speed gears)
considerations. The minimum pitch diameter of the pinion should be
d 1min = 2 x bore + 0.25 m (16.1)
where d is the bore diameter and m is the module expressed in mm.

2. As per Nuttall Works of the Westinghouse Electric and Manufacturing company, the
minimum thickness of metal t min between the keyway and the root circle shall be:

Z
t min  m (16.2)
5

3. The outside diameter of the hubs in larger gears should be 1.8 times the bore for
steel, 2 times for CI and 1.65 times for the forged steel. The hub length should be at
least 1.25 times the bore and never less than the width of the gear.

4. Design of the shaft is based on fatigue strength and rigidity considerations. (At the
contact region the deflection of the shaft should be less than 0.01 module, the slope of
the shaft at the radial bearing should be less than 0.008 radians and for self-aligning
bearings it should be less than 0.05 radians.

5. Bearings selection is based on 90% reliability for the following life:

8 hrs. operation per day life = 20,000 to 30,000 hrs.
8-16 hrs. operations per day life= 40,000-50,000 hrs.
16-24 hrs. operations per day life = 50,000-60,000 hrs.

6. Selection of lubricant is based on peripheral velocity, load, type of application and

operating temperature etc.
SAE 30, 40, 50, 60, 80, 90 are being recommended.
For low friction and high temperature operation synthetic oils are used.

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

7. Selection of method of lubrication is based on the peripheral speed. Up to a

peripheral speed of 15 m/s oil bath (oil immersion / splash) lubrication is used. Higher
depth of immersion is recommended for slow speed application. The maximum depth
should not exceed 100 mm. At higher speed the depth of immersion is reduced to cut
the churning losses. 0.7 tooth height or a minimum of 1 module is taken. However, the
depth of immersion should not be less than 10 mm. Generally recommended depth of
immersion is 3 to 4 times the module and a maximum of 6 modules. Above a peripheral
velocity of 15 m/s stream (jet) lubrication is used. Oil is delivered by a pump through a
filter and if necessary through a cooler directly to the teeth of gears as they are coming
out of mesh.

8. Quantity of oil required is given below by the thumb rule:

For splash lubrication Q = ( 2.5 - 8 ) L t litres or
Q = ( 0.35 - 0.7 ) W litres (16.3)
For spray lubrication rate of supply should be
Q e = 30 ( L t /ΔT) lpm (16.4)

where
L t - loss of power at the teeth contact ( kW )
W - is the power transmitted ( kW )
ΔT is the difference in oil temperature at the outlet and inlet in oC .

Q
Oil circulation timet '  Q min. (16.5)
e

t’ = 1 - 2.5 for splash lubrication with no external circulation where lack of space is
there in compact design.
t’ = 4 - 30 for oil circulation with cooling or reservoir.

9. Gear box housing design is based on thumb rule and thermal consideration.
The wall thickness of the CI housing can be found from the empirical formula:
s = 2 (0.1 T)0.25 ≥ 6 mm (16.6)

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

and that of the cover from: s c = 0.9 s (16.7)

where the T is torque on the slow speed shaft in Nm.
The diameter “d” of the bolts for securing the cover should be: d = (T)1/3 ≥ 10 mm
(16.8)
and that of foundation bolts:
d f =(2T)1/3 ≥ 12 mm (16.9)
The thickness of the foundation flange should be: s ff ≥ 1.5 d f .
(16.10)
The width of the flanges at the base and at the two halves of the housing should be:
w f = (2.1 to 2.5 )d (16.11)

Table 16.5 Alternate approach for wall thickness ‘s’ in mm for the gearboxes

Non-case hardened Case hardened gears

gears

CI castings 0.007L + 6 mm 0.010 L + 6 mm

Steel castings 0.005L + 4 mm 0.007L + 4 mm

Welded construction 0.004L + 4 mm 0.005L + 4 mm

where L is the largest dimension of the housing in mm.

Wall thickness of the load carrying upper half of the housing is taken as 0.8s, and that
for the non-load carrying upper half of the housing 0.5s.

Flange thickness is taken as 1.5s for castings and 2s for welded construction.

Outside dimension of the bearing housing is kept 1.2 times outside diameter of the
bearing.
Flange screw/bolt diameter = 1.2s casting & 1.5s for welded construction.
Bolt spacing 6-10 times the bolt diameter.

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

In designing reducing gear housing simple geometric shapes are to be preferred with
the outside as plain as possible. In order to reduce the air draft noises, the gap between
the gear and the side wall should be at least 15 mm.

Losses in gear boxes :

Total power loss L = L t + L ch + L b (16.12)

L t - power loss at tooth engagement.
L ch - churning power losses &
L b - bearing power losses

 1 1
L t  2.3 f    W kW (16.13) or
 Z1 Z 2 

 0.1 0.3 
Lt  W    kW (16.14)
 Z1 cos ψ V  2 

f - is the coefficient of friction between the teeth

Z 1 and Z 2 are number of teeth on the pinion and the gear,
V - peripheral velocity m/s and
ψ - helix angle

Table 16.6 Coefficient of friction for 20o pressure angle gears

V m/s 0.7 7 14 21 42

f 0.08 0.06 0.05 0.04 0.025

0.5
 200Vμ 
Lch  cb V   x 10 3 kW (16.15)
 Z1  Z 2 

Where
V - peripheral speed ( m/s)

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

b - face width of the gear ( mm )

c - factor equal to 0.009 for splash lubrication, 0.006 for stream lubrication
 - viscosity of oil at the operating temperature ( cP )

L b = 5.23 x 10-8 F f b d n kW (16.16)

where
F - radial load on the bearing ( N )
f b - coefficient of friction at the bearing reduced to the shaft diameter 0.005 - 0.01
d - shaft diameter ( mm )
n - shaft speed ( rpm )

The heat generated by the total power loss will raise the temperature of the oil and the
housing. The housing will dissipate heat H by radiation, convection and by conduction
through the foundation plate or the frame. When equilibrium conditions are set in the
heat generated and the heat dissipated will be the same. This equilibrium temperature
should be less that the maximum operating temperature for the oil otherwise the oil will
be getting oxidized. If the temperature exceeds then additional heat has to be dissipated
by separate cooling arrangement.

H = k t (T o – T a ) A (1+U) kcal/h (16.17)

where A - free surface of the housing from which heat is removed to cool the drive
(included is the 50% of the surface of the fins) m2.
T o & T a - temperature of the oil and the surrounding air, oC

k t - heat transfer coefficient, equal to 10 to 16 kcal / (m2 .oC .h) , larger values are
used under favourable conditions of air circulation; in new standard reducing gears, k t
=14 kcal/(m2. oC .h)

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Machine Design II Prof. K.Gopinath & Prof. M.M.Mayuram

U - factor taking into account heat transfer to the foundation plate or frame of the
machine and amounting up to 0.3 when the housing seating surface is large.

Heat generated per hour, H g = 3600000 L / J

Where J is the mechanical equivalent of heat

J = 4270 Nm / kcal
And L is the total power loss in kW
H g = 843 L (16.18)

Hd ≥ Hg (16.19)

And T o ≤ 93o C, otherwise provide heat exchanger for cooling the oil.

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