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Worm Gears New
Worm Gears New
d2 = m z 2
Worm
gear
d1 + d2 Worm
a= or screw
2
d1
Lw
N1 Z2 d2
i= =
N 2 Z1 d1
31-Mar-18 7:15 PM P R Venkatesh Mech Dept RVCE Bangalore 5
Terms used in worm Gears
z1 No of starts of the worm
z2 No of teeth on the worm gear
d1 Pitch diameter of the worm mz1
d 2 Pitch diameter of the worm gear mz2
d1 d 2
a Center distance =
2
pc axial the pitch of the worm
p2 Circular pitch of the worm gear
pc p2 12.46 (a) Page 220
lead of the worm l = pc z1 12.46 (b) Page 220
N1 Z 2 d 2
Velocity ratio i = 12.48 (c) Page 222
N 2 Z1 z1 pc
Safe design stress
31-Mar-18
d 4:24 PM in the
P R Venkatesh Mechgear, Bangalore
Dept RVCE Coefficient of friction 6
Definitions of terms used in worm Gears
Axial pitch pc : The axial pitch equals the circular pitch p2 of the worm gear.
Lead l : It is the axial advamce of a helix for one complete turn and is equal to
the number of threads times the axial pitch. i.e. l z1 pc
Lead angle : The slope of the thread is called the lead angle.
l
tan Eqn 12.100 Page 175
d1
Velocity ratio i' : The velocity ratio does not depend upon the diameters,
n z z d
but upon the number of teeth. i.e. i 1 2 2 2
n2 z1 z1 pc
Diametral quotient q : It is the ratio of pitch circle diameter d1 of the worm
d1
to the module of the worm gear. i.e. q
m
Note* * The worm gear may be specified by z1 / z2 / q / m For example,
d1
1 / 30 / 10 / 8 single start worm / 30 teeth gear / = 10 / module 8 mm
31-Mar-18 4:24 PM P R Venkatesh Mech Dept RVCE Bangalore
m
Design Procedure for Worm Gears :
Select hardened steel for worm & Phosphor bronze for gear.
Static stress for worm d 1 220.6 MPa (cast steel heat treated)
Static stress for worm gear d 2 82.4 MPa (Phosphor bronze)
Hence always design is based on the worm gear (weaker member)
Also based on velocity ratio i,select number of starts of worm z1
from Table 12.28 (b), page 244.
Step 1 : Tangential tooth load :
1000 P Cs
(a ) Based on power & rpm, Ft 12.7(a) Page 205
V
d 2 n2
P Power in KW, C s service factor =1.5 , V ( always )
60000
(b) Using Lewis equation, Ft d CvbYm 12.53 (a) Page 223
Take b = 10 m , d d 2 82.4MPa, Y y,
For y refer T 12.28(c) Page 244
Equating (a) & (b) theP module
31-Mar-18 4:24 PM m Dept
R Venkatesh Mech of the gear is determined.
RVCE Bangalore 8
Step 2 : Dimensions of worm gear & worm
Pitch dia of worm gear d 2 mz2 , b 10m
Ft ? Circular pitch p m axial pitch of worm pc
Pitch dia of worm d1 7.39m 10 mm [Table 12.26, Page 243]
Face length of worm Lw (14.14 0.063 z1 )m [Table 12.26, Page 243]
d1 d 2
Center distance a
2
l
Lead angle tan Eqn 12.46 (e) page223 As l z1 pc
d1
z1 pc z1 m mz1 1 mz1
& pc m, tan tan
d1 d1 d1 1
d
3 g
A Aw t2 t1 Eqn 12.63 (c), Page 227
0.407
Qd
10
where Projected area of the worm A w Lw d1 &
d 22
area of the worm gear A g
4
t2 gear temeperature, t1 ambient temperature
If Qd > Qg , no artifical cooling is necessary.
31-Mar-18 4:24 PM P R Venkatesh Mech Dept RVCE Bangalore 11
Problem 1 (Type I When no. of starts assumed)
Design a worm & worm wheel drive for a speed
reducer to transmit 3.5 KW at 600 rpm of the
worm. The velocity ratio is to be 25. The worm
gear teeth are 141/20 involute form. Assume the
gear temperature as 600C & room temperature as
300C.
Data :
n1 600
P 3.5 KW, i 25, n1 600 rpm, n 2 24 14.50
i 25
t g 600 C , t a 300 C , d 2 82.4 MPa (assuming phosphor bronze gear)
From Table 12.28 (b). Page 244, for velocity ratio > 20, z1 1
31-Mar-18 4:24 PM P R Venkatesh Mech Dept RVCE Bangalore 12
Solution :
Selecting hardened steel for worm & Phosphor bronze for gear.
Static stress for worm d 1 220.6 MPa (cast steel heat treated)
Static stress for worm gear d 2 82.4 MPa (Phosphor bronze)
Hence always design is based on the worm gear (weaker member)
Step 1 : Tangential tooth load : z1 1, z2 iz1 25 1 25 teeth
1000 P Cs
(a ) Based on power & rpm, Ft 12.7(a) Page 205
V
d 2 n2 mz2 n2 m 25 24
P 3.5 KW, C s 1.5 , V = = 0.03142m
60000 60000 60000
1000 3.5 1.5 167113
Ft (i)
0.03142m m
(b) Using Lewis equation, Ft d CvbYm 12.53 (a) Page 223
Take b = 10 m , d d 2 82.4MPa, Y y 0.1
1
0
y=0.1 for 14 from T 12.28 (c) Page 244
31-Mar-18 4:24 PM
2
P R Venkatesh Mech Dept RVCE Bangalore 13
Ft 82.4 Cv 10m 0.1 m 258.87m 2 C v (ii)
167113
Equating (i) & (ii) 258.87m 2
Cv m 3
Cv 645.55.
m
Assuming Cv 0.5, to get the initial trial value as m 3 2 RHS
m 3 2 645.5 10.88 mm.
Trial 1 : Let m 10 mm, V 0.03142m 0.3142 m / sec
6.1 6.1
Cv 0.951
6.1 V 6.1 0.3142
m3Cv 103 0.951 951 > 645.55 (required value)
Hence the selected module is safe.
Step 2 : Dimensions of worm gear & worm
Pitch dia of worm gear d 2 mz2 10 25 250 mm
Face
31-Mar-18width
4:24 PM of gear b P R10 m Mech
Venkatesh 10
10Dept RVCE 100 mm
Bangalore 14
Dimensions of worm gear & worm ....
167113 167113
Tangental tooth load Ft = =16711.3 N
m 10
Circular pitch p m 10 31.42 mm axial pitch of worm pc
Pitch dia of worm d1 7.39m 10 mm [Table 12.26, Page 243]
d1 7.39 10 10 84 mm
Face length of worm Lw (14.14 0.063z1 )m [Table 12.26, Page 243]
Lw (14.14 0.063 1) 10 142 mm
d1 d 2 84 250
Center distance a = 167 mm
2 2
mz1 1 10 1
Lead angle tan 1
tan 6.80
1
d 84
0.0422
Coefficient of friction 0.28 Eqn 12.60 (a), Page 226
vr
0.0422
0.28
0.0322
2.64
Also tan tan cos Eqn 12.56 (d) page 224
tan 1 tan cos tan 1 tan14.5 cos 6.8 14.40
Efficiency when the worm drives the worm wheel
cos tan cos14.4 0.0322 tan 6.8
78%
cos cot cos14.4 0.0322 cot 6.8
As efficiency is more than 50%, the drive is not self locking.
31-Mar-18 4:24 PM P R Venkatesh Mech Dept RVCE Bangalore 16
Step 4 : Heat generated & dissipated :
Amount of heat generated Q g Fn v r Eqn 12.63 (a), Page 227
Ft
[No cos in the denominator] Fn [To be remembered]
cos cos
16711.3
Fn 16822 N
cos 6.8 cos14.5
Q g 0.0322 16822 2.64 1430 J / sec
3 g
A Aw t2 t1 Eqn 12.63 (c), Page 227
0.407
Heat dissipated : Q d
10
where Projected area of the worm A w Lw d1 = 142 84 11928 mm 2
d 22 2502
area of the worm gear A g 49087 mm 2
4 4
t2 gear temeperature 600 C, t1 ambient temperature = 30 0 C
0.407
3
Qd 49087 11928 60 30 745 J / sec
10
As31-Mar-18
Qd < 4:24QgPM, artifical cooling is nece
P R Venkatesh Mechssary.
Dept RVCE Bangalore 17
Problem 2 (Type 2 When center distance is given)
Design a worm & worm gear drive for a speed
reducer to transmit 2 KW at 1200 rpm of the worm.
The speed ratio is to be 30 and the center distance
is to be 160 mm. The worm gear teeth are 200
involute form. Assume the gear temperature as
700C & room temperature as 250C.
Data : Center distance a 160 mm, P 2 KW, i 30, n1 1200 rpm
n1 1200
n2 40, 200 , t g 700 C , t a 250 C
i 30
d2 82.4 MPa (assuming phosphor bronze gear)
Here, the number of starts has to be determined, not assumed.
31-Mar-18 4:24 PM P R Venkatesh Mech Dept RVCE Bangalore 18
N1 1200
Solution : i = 30 Speed of worm gear N 2 40 rpm
N2 N2
d 1 220.6 MPa (Cast steel ) , d 2 82.4 MPa (Phosphor bronze)
Always worm gear is weaker. Hence design must be based on gear.
y2 0.125 for 20o tooth system. [Table 12.28 (c), Page 244]
a 0.875
As per AGMA, Pitch diameter of worm d1 12.51 (a), Page 223
1.466
1600.875
d1 60 mm,
1.466
d d2 60 d 2
Given a 1 160 d 2 260 mm
2 2
Tangential Tooth load : Based on power & rpm,
1000 PCs d N 260 40
(a) Ft Here v 2 2 0.545 m / sec
v 60000 60000
1000 2 1.5
Ft 5505 N
31-Mar-18 4:24 PM
0.545 P R Venkatesh Mech Dept RVCE Bangalore 19
(b) Based on Lewis equation, Ft d 2bCv mY
6.1 6.1
Here Cv 0.92
6.1 v 6.1 0.545
Y = πy2 = π 0.125, b = 10m
Ft 82.4×10m×0.92× m× 0.125 = 297.7m 2
Equating (a) &(b), 5505 = 297.7m 2 m = 4.3 5 mm
(Standard module from Table 12.2, Page 229)
Dimensions of worm gear :
d 2 260
(i) Number of teeth on worm gear z2 52
m 5
z2 52
(ii ) Number of starts on worm z1 1.73 2
i 30
z2 60 d 2 mz2 5 60 300 mm
31-Mar-18 4:24 PM P R Venkatesh Mech Dept RVCE Bangalore 20
Dimensions of worm & worm gear.....
d1 d 2 60 300
Corrected center distance a 180 mm
2 2
(iii ) Face width of worm gear b 10 m 10 5 50 mm,
(iv) Pitch p m 5 15.71 mm
Dimensions of worm :
(i) Pitch dia of worm d1 7.39m 10 (7.39 5) 10
d1 47mm 60 mm d1 60 mm
(ii) Face length of worm lw 14.14 0.063z1 m
Lw 14.14 0.063 2 5 71.33 mm
mz1 5 2
(iii) tan Lead angle 9.5 0
d1 60
31-Mar-18 4:24 PM P R Venkatesh Mech Dept RVCE Bangalore 21
Efficiency of the drive :
d1n1 60 1200
(i) Rubbing velocity vr 3.82 m / sec
60000 cos 60000 cos 9.5 0
3.281
(ii ) Coefficient of friction 0.025 vr Eqn 12.60 (b) Page 226
1000
3.281
( v r 2.75m / sec) 0.025 3.82 0.0375
1000
(iii ) tan tan cos tan 200 cos 9.50 0.36 19.730
cos tan cos19.730 0.0375 tan 9.50
(iv) Efficiency 0.81 81%
cos cot cos19.73 0.0375 cot 9.5
0 0
3.281
(ii ) Coefficient of friction 0.025 vr Eqn 12.60 (b) Page 226
1000
3.281
( v r 2.75m / sec) 0.025 7.38 0.049
1000
(iii ) tan tan cos tan 200 cos 6.520 0.36 19.8 0
cos tan
(iv) Efficiency
cos cot
cos19.80 0.049 tan 6.520
0.683 68.3%
cos19.80 0.049 cot 6.520
Check for thermal equilibrium :
Ft
(i ) Heat generated Q g Fn vr where Fn
cos cos
9202
Normal force Fn 0 0
9856 N
cos 6.52 cos 20
Q g 0.049 9856 7.38 3564 J / sec
31-Mar-18 7:02 PM P R Venkatesh Mech Dept RVCE Bangalore 28
3 g
A Aw t2 t1
0.407
(ii ) Heat dissipated Q d
10
d 2
320 2
Assume t2 650 C , t1 250 C , A g 2 80425 mm 2
4 4
A w lw d1 114 70 7980 mm 2
0.407
3
Qd 80425 7980 65 25 1439 J / sec
10
As Qd < Qg , artificial cooling is necessary.
d1 60
31-Mar-18 7:29 PM P R Venkatesh Mech Dept RVCE Bangalore 31
Power capacity of worm gear drive :
Based on Lewis equation, Ft d 2bCv mY Here, d 2 55 Mpa
d 2 n2
b 10m 10 5 50 mm, Y = πy2 = π 0.1, v =
60000
180 100
v 0.9425 m / sec
60000
3.05 3.05
By Barth's formula Cv 0.764
3.05 v 3.05 0.9425
Ft 55× 50×0.764× 5× 0.125 = 4125 N
1000 PCs
Also Ft Here Cs 1.0 (Given steady loads)
v
1000 P 1
4125 P 3.89 KW
0.9425
31-Mar-18 9:54 PM P R Venkatesh Mech Dept RVCE Bangalore 32
(ii) Efficiency of the drive by Barr's formula :
tan (1 tan )
Barr's formula is = Eqn 12.57(d), Page 225
tan
d1n1 60 1800
Rubbing velocity vr 5.73 m / sec
60000 cos 60000 cos 9.46 0
3.281
Coefficient of friction 0.025 vr Eqn 12.60 (b) Page 226
1000
3.281
( v r 2.75m / sec) 0.025 5.73 0.044
1000
tan (1 tan ) tan 9.460 (1 0.044 tan 9.460 )
0.785 = 78.5%
tan 0.044 tan 9.46 0