AGMA 6022 D19 WG

ANSI/AGMA 6022-D19
(Revision of ANSI/AGMA 6022-C93)
American National Standard
Standard for Design

Manual for Cylindrical
Wormgearing
ANSI/AGMA 6022-D19
AMERICAN NATIONAL STANDARD ANSI/AGMA 6022-D19
American Design Manual for Cylindrical Wormgearing

National ANSI/AGMA 6022-D19
Standard [Revision of ANSI/AGMA 6022-C93]
Approval of an American National Standard requires verification by ANSI that the
requirements for due process, consensus and other criteria for approval have been
met by the standards developer.
Consensus is established when, in the judgment of the ANSI Board of Standards
Review, substantial agreement has been reached by directly and materially affected
interests. Substantial agreement means much more than a simple majority, but not
necessarily unanimity. Consensus requires that all views and objections be
considered, and that a concerted effort be made toward their resolution.
The use of American National Standards is completely voluntary; their existence
does not in any respect preclude anyone, whether he has approved the standards or
not, from manufacturing, marketing, purchasing or using products, processes or
procedures not conforming to the standards.
The American National Standards Institute does not develop standards and will in no
circumstances give an interpretation of any American National Standard. Moreover,
no person shall have the right or authority to issue an interpretation of an American
National Standard in the name of the American National Standards Institute.
Requests for interpretation of this standard should be addressed to the American
Gear Manufacturers Association.
CAUTION NOTICE: AGMA technical publications are subject to constant
improvement, revision or withdrawal as dictated by experience. Any person who
refers to any AGMA Technical Publication should be sure that the publication is the
latest available from the Association on the subject matter.
[Tables or other self-supporting sections may be referenced. Citations should read:
See ANSI/AGMA 6022-D19, Design Manual for Cylindrical Wormgearing, published
by the American Gear Manufacturers Association, 1001 N. Fairfax Street, Suite 500,
Alexandria, Virginia 22314, http://www.agma.org.]
Approved September 9, 2019
ABSTRACT
This Design Manual provides information pertaining to selection of geometric parameters which will
constitute good design of fine and coarse pitch cylindrical wormgearing. The power rating for fine and
coarse pitch wormgearing is not included in this design manual, but can be found in AGMA 6034, Practice
for Enclosed Cylindrical Wormgear Speed Reducers and Gearmotors.
Published by:
American Gear Manufacturers Association
1001 N. Fairfax Street, Suite 500, Alexandria, Virginia 22314
Copyright © 2019 by American Gear Manufacturers Association
All rights reserved.
No part of this publication may be reproduced in any form, in an electronic
retrieval system or otherwise, without prior written permission of the publisher.
Printed in the United States of America
ISBN: 978-1-64353-066-6
©AGMA 2019 – All rights reserved i

Contents
Foreword ...................................................................................................................................................... vi
1 Scope ...................................................................................................................................................... 1
1.1 Uses of wormgearing .................................................................................................................. 1
1.2 Intended use................................................................................................................................ 1
2 Normative references ............................................................................................................................. 1
3 Symbols and terminology ....................................................................................................................... 1
3.1 Symbols....................................................................................................................................... 1
4 General design considerations ............................................................................................................... 3
4.1 Characteristics of wormgearing................................................................................................... 3
4.2 Loading........................................................................................................................................ 4
4.3 Ratios .......................................................................................................................................... 5
4.4 Conjugate action ......................................................................................................................... 5
4.5 Thread profile of worm ................................................................................................................ 6
4.5.1 Straight sided axial profile - Form ZA ........................................................................... 6
4.5.2 Straight sided normal profile - Form ZN ....................................................................... 7
4.5.3 Profile resulting from straight sided rotary milling cutter or grinding wheel - Form ZK. 7
4.5.4 Involute helicoid - Form ZI ............................................................................................ 8
4.5.5 Differences in commonly used profiles ......................................................................... 9
4.6 Accuracy requirements ............................................................................................................. 10
4.6.1 Worm accuracy ........................................................................................................... 10
4.6.2 Gear accuracy ............................................................................................................ 10
5 Design procedure ................................................................................................................................. 11
5.1 Number of teeth in the wormgear.............................................................................................. 11
5.2 Number of threads in the worm ................................................................................................. 12
5.3 Worm pitch diameter ................................................................................................................. 12
5.4 Wormgear pitch diameter .......................................................................................................... 12
5.5 Worm axial pitch ........................................................................................................................ 12
5.6 Worm lead ................................................................................................................................. 13
5.7 Lead angle of the worm ............................................................................................................. 13
5.8 Pressure angle .......................................................................................................................... 13
5.9 Customary thread and tooth proportions .................................................................................. 14
5.9.1 Worm and wormgear addendum ................................................................................ 14
5.9.2 Worm and wormgear dedendum ................................................................................ 14
5.9.3 Full depth of the worm thread ..................................................................................... 14
5.9.4 Normal chordal thread thickness of the worm ............................................................ 14
5.9.5 Worm outside diameter .............................................................................................. 15
5.9.6 Worm root diameter .................................................................................................... 15
5.9.7 Wormgear throat diameter.......................................................................................... 16
5.9.8 Wormgear root diameter ............................................................................................. 16
5.9.9 Wormgear outside diameter ....................................................................................... 16
5.9.10 Clearance ................................................................................................................... 16
5.9.11 Worm mean diameter ................................................................................................. 16
5.9.12 Worm face width (thread length of worm) .................................................................. 17
5.9.13 Wormgear face width .................................................................................................. 17
5.9.14 Wormgear basic dimensions ...................................................................................... 18
6 Modified tooth proportions .................................................................................................................... 18
6.1 High contact ratio designs ......................................................................................................... 18
6.2 Stub tooth designs .................................................................................................................... 19
©AGMA 2019 – All rights reserved ii

6.3 Recess and approach action..................................................................................................... 19

6.4 Design for additional or full recess action ................................................................................. 20
6.5 Alternative design for additional or full recess action gearing ................................................... 21
7 Contact patterns ................................................................................................................................... 21
7.1 Initial contact for power drive wormgearing .............................................................................. 22
7.2 Unacceptable initial contact ...................................................................................................... 22
7.3 Mounting and assembly problems and their effects on initial contact patterns ........................ 22
7.4 Other causes of variations in initial contact patterns ................................................................ 22
7.5 Wormgear contact under load ................................................................................................... 23
7.6 Special initial wormgear contact................................................................................................ 23
8 Run-in procedures ................................................................................................................................ 24
8.1 Definition of run-in ..................................................................................................................... 24
8.2 Results of run-in ........................................................................................................................ 24
8.3 Initial running at full load ........................................................................................................... 24
8.4 Initial friction at the mesh .......................................................................................................... 24
8.5 Recommended run-in period..................................................................................................... 25
8.6 Wormgear pitting ....................................................................................................................... 25
9 Rating and efficiency ............................................................................................................................ 25
10 Wormgear blank design ........................................................................................................................ 26
10.1 Typical wormgear blank configuration ...................................................................................... 26
10.2 Wormgear web configuration .................................................................................................... 26
10.3 Wormgear hub design ............................................................................................................... 26
11 Worm manufacturing practices ............................................................................................................. 26
11.1 Worm thread milling .................................................................................................................. 26
11.2 Worm thread milling with multiple milling cutters ...................................................................... 27
11.3 Worm thread hobbing ................................................................................................................ 27
11.4 Worm thread generating with a shaper cutter ........................................................................... 27
11.5 Worm thread rolling ................................................................................................................... 27
11.6 Worm thread grinding ................................................................................................................ 28
12 Wormgear manufacturing practices...................................................................................................... 28
12.1 Wormgear hobs ......................................................................................................................... 28
12.2 Wormgear hob design ............................................................................................................... 28
12.2.1 Hob oversize ............................................................................................................... 28
12.2.2 Hob profile .................................................................................................................. 28
12.2.3 Type of wormgear hob................................................................................................ 29
12.3 Wormgear flyhobbing ................................................................................................................ 29
13 Materials and heat treatment ................................................................................................................ 29
13.1 Worm materials ......................................................................................................................... 30
13.2 Wormgear materials .................................................................................................................. 31
13.2.1 Phosphor bronze ........................................................................................................ 31
13.2.2 Manganese bronze ..................................................................................................... 31
13.2.3 Alternate wormgear materials .................................................................................... 31
14 Lubrication ............................................................................................................................................ 31
14.1 Regimes of lubrication ............................................................................................................... 31
14.1.1 Metal-to-metal ............................................................................................................. 31
14.1.2 Boundary lubrication ................................................................................................... 31
©AGMA 2019 – All rights reserved iii

14.1.3 Full film lubrication ...................................................................................................... 32

14.2 Mineral oils ................................................................................................................................ 32
14.3 Synthetic oils ............................................................................................................................. 32
14.4 Splash lubrication ...................................................................................................................... 32
14.4.1 Oil level ....................................................................................................................... 32
14.4.2 Oil fill, vent, level and drain......................................................................................... 32
14.5 Forced feed lubrication .............................................................................................................. 32
14.5.1 Location of spray nozzles ........................................................................................... 32
14.5.2 Forced feed lubrication with cooling ........................................................................... 32
15 Analysis of gearing forces, worm bending stress and deflection ......................................................... 33
15.1 Tangential, separating and thrust forces ................................................................................... 33
15.1.1 Wormgear tangential force ......................................................................................... 33
15.1.2 Separating force ......................................................................................................... 34
15.1.3 Wormgear thrust force ................................................................................................ 34
15.2 Worm bearing reactions ............................................................................................................ 34
15.3 Worm bending stress ................................................................................................................ 35
15.4 Allowable worm bending stress................................................................................................. 35
15.5 Worm deflection ........................................................................................................................ 36
15.5.1 Equations for determining worm deflection ................................................................ 36
15.5.2 Allowable worm deflection .......................................................................................... 37
16 Assembly procedures ........................................................................................................................... 37
16.1 The housing............................................................................................................................... 37
16.2 Position tolerance ...................................................................................................................... 37
16.3 Contact pattern check ............................................................................................................... 38
16.4 Backlash check ......................................................................................................................... 38
16.5 End play check .......................................................................................................................... 38
Annex A (informative) Formulas for worm thread profiles .......................................................................... 39
A.1 Purpose ..................................................................................................................................... 39
A.2 Form on involute worm .............................................................................................................. 39
A.3 Form on ZK worm ..................................................................................................................... 39
A.4 Reduction of normal pressure angle ......................................................................................... 40
Annex B (informative) Sources of formulas used for determining worm thread profiles............................. 41
B.1 Purpose ..................................................................................................................................... 41
B.2 References ................................................................................................................................ 41
Annex C (informative) Sources of information concerning hob design ....................................................... 42
C.1 Purpose ..................................................................................................................................... 42
C.2 References ................................................................................................................................ 42
Annex D (informative) Worm thread profiles - axial sections ...................................................................... 43
Annex E (informative) Bibliography ............................................................................................................. 44
Tables
Table 1 – Symbols and terms ....................................................................................................................... 2
Table 2 - Suggested minimum number of wormgear teeth for customary designs .................................... 11
Table 3 - Suggested minimum number of wormgear teeth for modified designs ....................................... 21
©AGMA 2019 – All rights reserved iv

Figures
Figure 1 - Lines of contact on wormgear teeth ............................................................................................. 4
Figure 2 – Relative radii of curvature ............................................................................................................ 4
Figure 3 - Number of teeth in contact ........................................................................................................... 5
Figure 4 - Rack profiles of worms ................................................................................................................. 6
Figure 5 - Form ZA ........................................................................................................................................ 7
Figure 6 – Form ZN ....................................................................................................................................... 7
Figure 7 - Form ZK ........................................................................................................................................ 8
Figure 8 - Form ZI ......................................................................................................................................... 9
Figure 9 - Profile measurement of form ZI .................................................................................................... 9
Figure 10 - Tooth spacing accuracy changes - 30 tooth wormgear ........................................................... 10
Figure 11 - Tooth spacing accuracy changes - 29 tooth wormgear ........................................................... 11
Figure 12 - Variation of lead angle .............................................................................................................. 13
Figure 13 - Normal chordal thread thickness of worm ................................................................................ 15
Figure 14 - Worm face width ....................................................................................................................... 17
Figure 15 - Wormgear face width ................................................................................................................ 18
Figure 16 - Wormgear basic dimensions - customary proportions ............................................................. 19
Figure 17 - Approach and recess action - customary proportions .............................................................. 20
Figure 18 - Approach and recess action - modified proportions ................................................................. 21
Figure 19 - Initial no-load wormgear contact .................................................................................................. 23
Figure 20 - Initial no-load wormgear contact variations due to wormgear tooth spacing errors even
ratio (40/2 = 20 ratio) .................................................................................................................... 23
Figure 21 - Special initial no-load wormgear contact .................................................................................. 24
Figure 22 - Typical wormgear blank configuration minimum rim thickness...................................................... 27
Figure 23 - Generation of wormgear teeth .................................................................................................. 28
Figure 24 - Hobbing of wormgears ............................................................................................................. 30
Figure 25 - Flytool hobbing of wormgears .................................................................................................. 30
Figure 26 - Worm and wormgear forces - RH thread ................................................................................. 35
Figure 27 - Worm bearing reactions ........................................................................................................... 36
Figure 28 - Equivalent beam for worm ........................................................................................................ 36
©AGMA 2019 – All rights reserved v

Foreword
[The foreword, footnotes and annexes, if any, in this document are provided for informational purposes
only and are not to be construed as a part of AGMA Standard 6022-D19, Design Manual for Cylindrical
Wormgearing.
The standard provides a broad range of design parameters for fine and coarse pitch cylindrical
wormgearing which would constitute feasible design, within which the designer may search for a better
design. The greatest possible latitude for design has been sought.
The earlier standard AGMA 341.01, was approved by the AGMA membership in June 1955, and AGMA
341.02 was approved by the membership in December 1964 and reaffirmed in May 1970.
Standard AGMA 374.01, Design for Fine-Pitch Wormgearing has been withdrawn.
Data contained herein represents a consensus from among engineering representatives of member
companies of AGMA and other interested parties.
AGMA Standards are subject to constant improvement, revision, or withdrawal as dictated by experience.
Any person who refers to AGMA technical publications should satisfy himself that he has the latest
information available from the Association on the subject matter.
ANSI/AGMA 6022-D19 replaces ANSI/AGMA 6022-C93. It was created to change the formatting from
dual to single column and to implement a few minor editorial changes.
The first draft of ANSI/AGMA 6022-D19 was created in January 2019. It was approved by the
membership in July, 2019 and as an American National Standard on September 9, 2019.
Suggestions for improvement of this standard may be submitted to tech@agma.org.
©AGMA 2019 – All rights reserved vi

PERSONNEL of the AGMA Cylindrical Wormgearing Committee
Chairman: Martin Peculis ............................................... Cleveland Gear

Vice Chairman: Eric Ayers ............................................. Boston Gear
ACTIVE MEMBERS
Robert Holdsworth ......................................................... Peerless-Winsmith, Inc.

Ernie Reiter .................................................................... Web Gear Services Ltd.
Massimiliano Turci ......................................................... Studio Tecnico Turci
R. Gregory Estell ............................................................ The Estell Group
Terrance Klaves ............................................................. Terrance Klaves
©AGMA 2019 – All rights reserved vii

American National Standard –
Design Manual for Cylindrical Wormgearing

1 Scope
This design manual covers the design of fine and coarse pitch cylindrical wormgearing operating at right
angles and primarily made as gear sets to be incorporated into other machines and mechanisms. Many of
the design procedures are also incorporated in enclosed drives.
1.1 Uses of wormgearing

Wormgearing is used on applications transmitting very small amounts of power up to 1000 HP (746KW)
and 10 lb in (1.13 Nm) up to 3 000 000 lb in (339 000 Nm) output torques. Worm speeds can vary from 0
to 10 000 rpm, depending on size. Design of wormgearing varies with its specific uses and application
requirements. Wormgearing used in an indexing mechanism of a machining center has different
requirements from a conveyer drive in a steel mill.
1.2 Intended use

The equations and values presented provide a general approach to design. Deviations from the methods
and values stated in this design manual may be made when justified by experience, testing, or more
specific analysis. It is intended for use by experienced gear designers capable of selecting reasonable
values based on their knowledge of the performance of similar designs and the effect of such items as
lubrication, deflection, manufacturing tolerances, metallurgy, residual stresses, and system dynamics. It
is not intended for use by the engineering public at large. Because of the wide variety of applications of
wormgearing, this design manual is a practical overview of wormgearing design and is intended as a
guideline for users and manufacturers in the general principles of operation, the basic design concepts
and formulas, the common thread forms used, the use of modified designs, tooling and manufacturing
considerations, and the proper mounting, assembly and run-in of wormgearing.
2 Normative references
The following documents contain provisions which, through reference in this text, constitute provisions of
the standard. At the time of publication, the editions were valid. All publications are subject to revisions,
and the users of the manual are encouraged to investigate the possibility of applying the most recent
editions of the publications listed.
ANSI/AGMA 6034-B92, Practice for Enclosed Cylindrical Wormgear Speed Reducers and
Gearmotors
AGMA 6001-F19, Design and Selection of Components for Enclosed Gear Drives
3 Symbols and terminology

3.1 Symbols
The symbols, terms, and definitions, when applicable, conform to ANSI/AGMA Standard 1012--G05, Gear
Nomenclature, Definitions of Terms with Symbols as shown in Table 1.
©AGMA 2019 – All rights reserved 1

Table 1 – Symbols and terms
Symbols Definition Units First used First referenced

Distance from wormgear pitch
A in (mm) Equation 37 15.2
point to bearing B
Worm and wormgear
a in (mm) Equation 8 5.9.1
addendum
B Axial backlash in (mm) Equation 13 5.9.4
Worm and wormgear
b in (mm) Equation 9 5.9.2
dedendum
C Center distance in (mm) Equation 2 5.3
c Clearance in (mm) Equation 21 5.9.10
D Wormgear pitch diameter in (mm) Equation 4 5.4
Dm Wormgear mean diameter in (mm) Equation 34 15.1.1
Do Wormgear outside diameter in (mm) Equation 20 5.9.9
Dr Wormgear root diameter in (mm) Equation 19 5.9.8
Dt Wormgear throat diameter in (mm) Equation 18 5.9.7
d Worm pitch diameter in (mm) Equation 2 5.3
db Worm base circle diameter in (mm) Figure 9 4.5.4
dm Worm mean diameter in (mm) Equation 22 5.9.11
do Worm outside diameter in (mm) Equation 16 5.9.5
dr Worm root diameter in (mm) Equation 17 5.9.6
Modulus of elasticity lb/in2 Equation 43 15.5.1
E
N/mm2
F Equivalent load lb (N) Equation 41 15.5.1
FG Wormgear face width in (mm) Equation 25 5.9.13
Worm face width (Thread length in (mm) Equation 24 5.9.12
FW
of worm)
ht Full depth of worm thread in (mm) Equation 11 5.9.3
Moment of inertia of worm cross in4 (mm4) Equation 43 15.5.1
I
sectional area
k Location factor -- Equation 42 15.5.1
L Lead of the worm thread in (mm) Equation 6 5.6
l Bearing span in (mm) Equation 37 15.2
M Bending moment lb in (Nm) Equation 39 15.3
mG Wormgear ratio -- Equation 1 5.2
N Normal tooth load lb (N) Figure 17 6.3
NG Number of teeth in wormgear -- Equation 1 5.2
NW Number of threads in worm -- Equation 1 5.2
p Wormgear circular pitch in (mm) Equation 5 5.5
px Worm axial pitch in (mm) Equation 5 5.5
Resultant of rolling friction and lb (N) Figure 17 6.3
R
normal load

Symbols Definition Units First used First referenced

RA Bearing A radial load lb (N) Equation 37 15.2
RB Bearing B radial load lb (N) Equation 38 15.2
Radius of curvature of worm in (mm) Figure 2 4.1
R1
thread profile
Radius of curvature of in (mm) Figure 2 4.1
R2
wormgear tooth profile
Worm shaft bending stress lb/in2 Equation 40 15.3
Sb
N/mm2
TG Wormgear torque lb in (Nm) Equation 34 15.1.1
Tw Torque at worm shaft lb in (Nm) Equation 36 15.1.3
Normal chordal thread in (mm) Equation 13 5.9.4
tnc
thickness of the worm
Wag Wormgear thrust force lb (N) Equation 36 15.1.3
Wsg Wormgear separating force lb (N) Equation 35 15.1.2
Wtg Wormgear tangential force lb (N) Equation 34 15.1.1
Waw Worm thrust force lb (N) Equation 34 15.1.1
Wsw Worm separating force lb (N) Equation 35 15.1.2
Wtw Worm tangential force lb (N) Equation 36 15.1.3
y Worm shaft deflection in (mm) Equation 43 15.5.1
Lead angle at the worm pitch degrees Equation 7 5.7
λ
diameter
λb Worm base lead angle degrees Figure 9 3.5.4
Lead angle at worm mean degrees Figure 6 4.5.2
λm
diameter
ηw Worm driving efficiency -- Equation 31 9
ηg Wormgear driving efficiency -- Equation 32 9
Normal pressure angle at the degrees Figure 8 4.5.4
φn
worm mean diameter
µ Coefficient of friction -- Equation 31 9
µstatic Static coefficient of friction Equation 33 9
4 General design considerations

Successful application of wormgearing begins with an understanding of the unique characteristics of
wormgearing and a consideration of the requirements of the application.
4.1 Characteristics of wormgearing

Wormgearing consists of a threaded input member (worm) driving a larger toothed wormgear at right
angles. By restraining the rotating worm axially the wormgear is made to turn. As the worm rotates
through the wormgear tooth, lines of contact roll or progress from the tip to the root of the wormgear
tooth. As shown in Figure 1, at any given instant there may be 2 – 3 teeth in contact in varying positions
rolling through the worm threads. These 2 – 3 lines of contact on 2 – 3 wormgear teeth transmit power.
The movement of this line of contact on each wormgear tooth from tip to root results in an area of contact
marking on each wormgear tooth. The stresses developed along the lines of contact are surface and

subsurface stresses related to the load, the relative radii of curvature of the worm thread and wormgear
tooth, the distribution of load between the teeth, and the sliding friction forces caused by the rotation of
the worm. If the relative curvature of the worm and wormgear surfaces at the line of contacts is as large
as shown in Figure 2, the line of contact, when under load, will have some finite band width or area.
Particularly in designs with low ratio and high lead angle, these radii vary considerably across the face, so
the band width of the contact will also vary across the face as will the surface and subsurface stresses.
Equalization of load among the lines of contact on the 2 -- 3 wormgear teeth transmitting the total load is
an important consideration in minimizing contact stresses.
Figure 1 - Lines of contact on wormgear teeth
Figure 2 – Relative radii of curvature
4.2 Loading
Based on Clause 4.1, the design of wormgearing should be tailored to the type of load and speed to be
transmitted. For transmission of significant amounts of power at high speed, a relatively fine pitch
wormgear should be used while high torques at low speeds require large worm diameters and coarse
pitches. When smoothness of transmission with low noise and vibration is a requirement, fine pitches with
low pressure angles are preferred.

4.3 Ratios
Wormgearing can be produced with 1 : 1 through 360 : 1 ratios although the usual catalogued ratio range
is 3 : 1 through 100 : 1. The ratio is the number of teeth in the wormgear divided by the number of teeth
or threads in the worm. Ratios above 30 : 1 are usually produced with a single thread worm and ratios
lower than 30 :1 favor the use of multiple threads. However, there can be exceptions to this. If high
wormgear tooth strength is required, it may be desirable to design a 25-tooth wormgear with a single start
worm. Yet for the usual application, it is desirable to use a 49 or 50-tooth wormgear with a 2-start worm.
Note that, with normal design procedures, the number of wormgear teeth in contact with the worm for any
given ratio is the same no matter what number of worm starts and number of wormgear teeth are used.
See Figure 3.
Generally, the larger the center distance, the greater the number of threads should be selected; for
example, a 1 inch (25.4 mm) center distance 20 : 1 design could be made as a 20/1 design but a 36 inch
(914.4 mm) center distance wormgear would be more likely designed with 59 or 60 teeth in the wormgear
and 3-threads in the worm for a 59/3 = 19-2/3 or 60/3 = 20 ratio.
41/2 = 20.5 80/4 = 20-0/4 = 20

20° Pressure Angle 20° Pressure Angle
Figure 3 - Number of teeth in contact
In the design or selection of ratios requiring multiple thread worms, there are two tooth combination
systems that can be used. One is the even number system where the number of teeth in the wormgear
can be evenly divided by the number of threads in the worm, for example (40/2 = 20:1). The hunting
tooth ratio system uses a combination of wormgear teeth and worm threads where the number of teeth in
the wormgear is not evenly divisible by the threads of the worm, for example (39/2 = 19.5:1). Over the
years, there has been a difference of opinion of the benefit of one system over the other. Utilizing current
state of the art manufacturing equipment, tools, and technology has resulted in either of the two systems
performing suitably in virtually all types of applications.
In designs requiring precision, motion transmission, or designs that are extremely cost sensitive, further
investigation of the hunting tooth wormgear system versus even number wormgear system may be
required.
4.4 Conjugate action

For gears, two surfaces are conjugate if one generates the other when both are rotated at a specified
relative uniform motion. In wormgearing, the worm, when rotated, results in a series of rack profiles being
advanced along its axis as shown in Figure 4.
As can be seen in Figure 4, the center section has identical pressure angles on both flanks, but off-center
sections are not symmetrical. In any case, the hob that generates the wormgear teeth has an identical
series of rack sections that generate the wormgear teeth, so that conjugate action in a wormgear is
essentially the same as conjugate action between a rack and pinion. The particular shape of the rack

profiles from tip to root does not affect the conjugacy as long as the worm and the wormgear hob have
the same profile type and pressure angle (see Figure 4).
4.5 Thread profile of worm

The thread profile or shape of the thread flanks can be described by the method used for the manufacture
of the worm. No limitation is placed on the method used except that the hob or tooling used to produce
the wormgear should have substantially the same profile as the worm so that the mating wormgear has
proper contact with the worm, and the gear pair provides uniform transmission of motion. Some tip and
root relief for the wormgear as well as oversize and short lead for the hob is frequently used to provide
"crowning” of the wormgear teeth to assure the uniform transmission of motion and prevent excessive
noise, dynamic loads, and vibration. Because of the number of different thread profiles in use, it is
generally desirable that the worm and wormgear be manufactured by the same supplier to assure proper
mating. While successful applications are possible with any of the common thread forms in use, some
profiles are more suited to particular applications than others depending on speed, ratio and degree of
accuracy required.
Figure 4 - Rack profiles of worms
4.5.1 Straight sided axial profile - Form ZA

This profile can be produced with a straight sided lathe tool placed on the axial plane as shown in Figure
5.
If a rotary milling cutter or a grinding wheel is used to produce a ZA profile worm thread, such a cutter or
grinding wheel would require convex profiled cutting edges. Profile variations of the worm are easily
checked for this Form ZA profile since it is a straight line in the axial plane. The central section of the
mating wormgear is theoretically an involute shape and its profile variations can be checked with an
involute checker.

Figure 5 - Form ZA
4.5.2 Straight sided normal profile - Form ZN
Figure 6 – Form ZN
This profile is produced with a straight sided lathe tool with its cutting face tilted to the lead angle of the
thread at its mean diameter as shown in Figure 6.
As with Form ZA profiles, a suitably convex profiled rotary or conical milling cutter or grinding wheel would
have to be used to produce Form ZN profile.
4.5.3 Profile resulting from straight sided rotary milling cutter or grinding wheel - Form ZK
This profile is a convex profile in the axial and normal planes of the worm resulting from the use of a
straight sided milling cutter or grinding wheel with its axis tilted to the lead angle of the thread at its mean

diameter. The center plane of the cutter or wheel must intersect the axis of the worm at the centerline of
the thread space. The shape of the thread flank produced is dependent on the diameter of the cutter or
grinding wheel due to the generating action of the tool. See Figure 7.
Profile variations of Form ZK profiles on finished worms must be measured relative to a convex curve with
a varying pressure angle, top to bottom, and as a result are not as easily determined. The main
advantage of this form is the ease of sharpening the cutter or dressing the grinding wheel.
Figure 7 - Form ZK
4.5.4 Involute helicoid - Form ZI

This thread profile can be produced one flank at a time by a flat sided cutter or grinding wheel whose axis
is tilted to the lead angle of the worm at its mean diameter and also inclined to the desired pressure angle
of the worm at its mean diameter as shown in Figure 8.
The profile produced by this method is a convex curve in both the normal and axial planes of the worm
and is independent of the diameter of the cutter or grinding wheel. The sharpening of the cutter or
dressing of the grinding wheel is easily controlled in this method because it is a flat surface perpendicular
to the cutter or wheel axis. Desired profile of the resulting worm is a straight line at the off center section
at the base radius and base lead angle (see Figure 9). Profile variation relative to this straight line is
easily inspected if proper inspection equipment is available (see Figure 9).
If both flanks of an involute worm are to be ground at the same time, the rotary cutter or grinding wheel
can be tilted to the lead angle at the worm mean diameter and not inclined to the normal pressure angle.
However, the cutter or wheel must be properly vee shaped with concave profiled flank forming surfaces in
order to obtain the desired involute shape. Sharpening the cutter or dressing the grinding wheel is more
difficult and the profile of the worm obtained varies with grinding wheel diameter in this method, but the
desired worm profile and its variations can still be inspected by the same straight-line method shown in
Figure 9.

Figure 8 - Form ZI
Figure 9 - Profile measurement of form ZI
4.5.5 Differences in commonly used profiles

Annex D shows typical thread profiles in the axial plane for the commonly used forms ZA, ZN, ZK with
milling cutter, ZK with grinding wheel, and ZI. The amount of curvature varies with each form and is
shown for approximately 1 in (25 mm), 2 in (50 mm), and 8.5 in (216 mm) mean diameter worms with
nominally 10:1 and 50:1 reductions.
The differences in curvature are very slight for the smaller sizes and higher ratio examples but are
significant in the larger sizes and lower ratios. A 3:1 or a 5:1 ratio, particularly, would show more

significant differences in profile no matter what size is calculated. The actual profile used and the amount
of curvature obtained is not as significant as the accuracy with which the wormgear tooth profile matches
the particular worm profile selected.
4.6 Accuracy requirements

The proper operation and long life of wormgearing depends on the accuracy of manufacturing even
though an application has no special requirements for noise level, accuracy of transmission or index.
4.6.1 Worm accuracy

The accuracy of worm dimensions (i.e., its runout, lead variations, profile variations, and thread spacing
variations for multiple thread worms) are most important because the worm is the harder member and is
subject to many more stress cycles than the wormgear.
4.6.2 Gear accuracy

The wormgear is usually made from the softer material and as such any initial minor tooth spacing
variations as well as minor profile variations will be greatly reduced with a few hours of operation. Figure
10 illustrates the improvement in wormgear tooth spacing variations of a particularly inaccurate wormgear
after six hours and after 200 hours of initial running. However, excessive wormgear tooth runout will tend
to accelerate the wormgear every half a revolution causing contact area variations and increased loads.
Excessive face runout or wobble, either in hobbing or mounting of the wormgear, will also cause the
wormgear contact to shift across the face, allowing the wormgear to accelerate and decelerate every
revolution.
Figure 11 illustrates the improvement in wormgear tooth spacing variations after run-in of an initially more
accurate hunting tooth ratio, 29 tooth wormgear. The wormgear accuracy after run-in is about the same
as the even ratio 30 tooth wormgear in Figure 10 because the worm thread spacing variations of the
worm used are identical.
Figure 10 - Tooth spacing accuracy changes - 30 tooth wormgear

Figure 11 - Tooth spacing accuracy changes - 29 tooth wormgear
5 Design procedure
The development of a wormgear design varies considerably with the intended end use and other design
criteria. In some instances, available manufacturing tooling may be the primary determinant of the detail
wormgear geometry. In other designs, physical or space restriction may govern the design. The
following data and formulas are offered as a guideline for the usual design procedures and are presented
in the steps that a designer would normally have to take knowing the gear ratio and the size or center
distance between the worm and wormgear. The dimensions calculated are illustrated in Figure 16.
Modified gearing designs are not covered here but are discussed in Clause 6.
5.1 Number of teeth in the wormgear

The number of teeth in a wormgear is determined by the required ratio and the minimum number of teeth
required for acceptable design. Refer to Table 2 for suggested minimum number of teeth for customary
designs. Consideration must also be given to the relationship between the strength and durability of the
gear teeth, center distance, ratio, worm diameter, lead angle, thread profile and tool design based on the
loads to be transmitted. Refer to Clause 4.2 and Clause 4.3 for loading and ratio considerations.
Table 2 - Suggested minimum number of wormgear teeth for customary designs
For normal pressure angle of: Minimum number of wormgear teeth
(customary designs)
14.5° 40
17.5° 27
20° 21
22.5° 17
25° 14
27.5° 12
30° 10

5.2 Number of threads in the worm

The number of threads in the worm is determined by the number of teeth in the wormgear and the
required ratio.
NG
NW = (1)
mG
where
NW is the number of threads in the worm (must be an integer);
NG is the number of teeth in the wormgear;
mG is the ratio (refer to Clause 4.3).
The normal range of the number of threads in the worm is one to ten although larger numbers are used,
particularly for larger wormgears.
5.3 Worm pitch diameter

For usual application, a worm pitch diameter is selected to fall within the following ranges:
C 0.875
d max = (2)
1.6
C 0.875
d max = (2M)
1.07
C 0.875
d min = (3)
3.0
C 0.875
d min = (3M)
2.0
where
d is the worm pitch diameter, in (mm);
C is the center distance, in (mm).
Worm pitch diameters near the maximum size should be selected when the strength of the gear set is of
prime importance. Not only is a larger diameter worm stronger due to its size, but the increased diameter
allows for a wider face width making the wormgear teeth stronger. The gear set efficiency will be higher
when the pitch diameter of the worm is smaller, but the resulting worm root diameter should be checked
for bending stresses and deflections based on the bearing span used and the loads to be transmitted.
5.4 Wormgear pitch diameter

The wormgear pitch diameter is calculated as follows:
D 2C − d
= (4)
where
D is the wormgear pitch diameter, in (mm).
5.5 Worm axial pitch

The worm axial pitch is the distance in the axial plane from a point on one thread of the worm to the
corresponding point on the next thread. It must equal the circular pitch of the gear. In fact, the worm and
wormgear pitch diameters are defined as those diameters where the circular pitch of the wormgear
equals the axial pitch of the worm.

πD
p=
x p= (5)
NG
where
px is the worm axial pitch, in (mm);
p is the circular pitch of the wormgear, in (mm).
When change gears are used to either mill or grind the worm or hob the gear, the axial pitch should equal
some simple fraction to permit accurate factoring for the change gear ratios.
5.6 Worm lead

The worm lead is the amount of the axial advance of any point on the worm in one revolution of the worm.
L = NW p x
(6)
where
L is the lead, in (mm).
5.7 Lead angle of the worm

The lead angle is calculated as follows:
L
λ =tan −1 (7)
πd
where
λ is the lead angle at the worm pitch diameter, degrees.
Note that the lead angle may vary considerably from the worm outside diameter to its root diameter as
shown in Figure 12.
Figure 12 - Variation of lead angle
5.8 Pressure angle

Customary pressure angles for wormgearing are 14.5°, 17.5°, 20°, 22.5°, 25°, 27.5° and 30° although
other pressure angles can be used. The pressure angle selection is based on the requirements of the
application. Higher pressure angles are used where high wormgear tooth strength is required, but usually
results in fewer teeth in contact, higher bearing reaction loads and greater worm bending stresses and
deflections (refer to Table 2 or Table 3).

5.9 Customary thread and tooth proportions
5.9.1 Worm and wormgear addendum

px
a
= = 0.3183 p x (8)
π
where
a is the addendum of worm and wormgear, in (mm).
5.9.2 Worm and wormgear dedendum

1.157 p x
=b = 0.3683 p x (9)
π
(for px greater than 0.160 in [4.06 mm])
or
1.200 p x
b= + 0.002= 0.3820 p x + 0.002 (10)
π
1.200 p x
b= + 0.0050 = 0.3820 p x + 0.050 (10M)
π
(for px equal to or less than 0.160 in [4.06 mm])
where
b is the dedendum of the worm and wormgear, in (mm).
5.9.3 Full depth of the worm thread
2.157 p x
=ht = 0.6866 p x (11)
π
(for px greater than 0.160 in [4.06 mm])
2.200 p x
h=
t + 0.002= 0.7003 p x + 0.002 (12)
π
(for px equal to or less than 0.160 in [4.06 mm])
2.200 p x
h=
t + 0.050= 0.7003 p x + 0.050 (12M)
π
where
ht is the full depth of worm thread, in (mm).
5.9.4 Normal chordal thread thickness of the worm

Refer to Figure 13.
Many different methods of establishing this thread thickness are used to assure that worm thread or
wormgear tooth tip thicknesses do not come to a point (particularly for the higher pressure angles) or to
suit the loads to be transmitted. The usual calculation is as follows:
p 
t nc = x − B  cos λ m (13)
 2 
 
where
tnc is the normal chordal thread thickness at a thread depth equal to the addendum, in (mm);

px is the worm axial pitch, in (mm);

B is the allowance for backlash in the axial plane of the worm, in (mm).
L
λm =tan −1 (14)
πd m
where
λ m is the worm mean lead angle;
L is the lead, in (mm);

d m is the worm mean diameter, in (mm) (see Clause 5.9.11).
Because the steel worm thread is stronger than the bronze wormgear teeth, larger worms are sometimes
arbitrarily made less than one half the pitch as follows:
Figure 13 - Normal chordal thread thickness of worm

t nc = ( 0.45 p x − B ) cos λ m (15)
5.9.5 Worm outside diameter

d o= d + 2a (16)
where
do is the worm outside diameter, in (mm).
Note that rolled threads may have material beyond the active profile of the thread so that the actual
outside diameter may be slightly larger than determined by the above formula.
5.9.6 Worm root diameter

d r= d − 2b (17)
where
dr is the worm root diameter, in (mm).
Worm stress and deflection should be checked at this point based on the loads to be transmitted. See
Clause 14 for calculation methods.

5.9.7 Wormgear throat diameter

D=
t D + 2a (18)
where
Dt is the wormgear throat diameter, in (mm).
5.9.8 Wormgear root diameter

D=
r D − 2b (19)
where
Dr is the wormgear root diameter, in (mm).
5.9.9 Wormgear outside diameter

The determination of the wormgear outside diameter is not an exact procedure.
D=
o Dt + a approximated to the next common wormgear blank (20)
where
Do is the wormgear outside diameter, in (mm).
NOTE: Current practices for producing fine pitch (px equal to or less than 0.160 in [4.06 mm]) wormgear blanks do
not require throating. This results in a much simpler blank which is quite similar to a spur or helical gear blank.
The slight loss in contact can be ignored since it adds little to the load carrying capacity of fine pitch wormgears.
It is sometimes desirable to use topping hobs for producing wormgears which are required to have close control
of size relation between the throat and pitch diameters. In such cases, the blank is made slightly larger.
The difference between the throat diameter and blank diameter will vary with the pitch. Usually 0.005 to 0.010
inch (0.127 to 0.254 mm) topping stock allowance on a side is sufficient.
5.9.10 Clearance
This is the running clearance between the throat of the wormgear and the root of worm and between the
worm outside diameter and the root of the wormgear.
c= b − a (21)
where
c is the clearance, in (mm).
5.9.11 Worm mean diameter

d m = d o − 2a = d for customary proportions (22)
or
d o + d r + 2c
dm = (23)
2
for modified proportions,
where
dm is the worm mean diameter, in (mm).
For standard proportions, the worm mean diameter is equal to the worm pitch diameter. However, for
nonstandard proportions, the worm mean diameter can be very different from the pitch diameter and the
mean diameter should be used for efficiency and rating calculation purposes.

5.9.12 Worm face width (thread length of worm)

Refer to Figure 14.
2 2
D  D 
F=
W max 2  t  − − a (24)
 2  2 
where
FW max is the worm face width, in (mm).
If the number of threads in contact with wormgear teeth is the usual 2 to 3, the worm face width can be
reduced from the above value such that the face width of the worm is equal to five times px which
provides for the three contacting threads plus one extra thread at each end to provide support for the load
carrying threads.
Figure 14 - Worm face width
5.9.13 Wormgear face width

The determination of wormgear face width, FG, is not an exact procedure. For circular pitch, px, exceeding
0.160 in (4.06 mm), the usual procedure is to exceed the minimum value established in the power rating
formulas given in ANSI/AGMA 6034-B92.
FG = 0.67 d m (25)
where
FG is the actual wormgear face width, in (mm).
For circular pitches equal to or less than 0.160 in (4.06 mm), the usual procedure is to calculate the
wormgear face width as follows:
( d o + 2c ) − ( d o − 4a )
2 2
FG 1.125
= (26)
where
FG is the actual wormgear face width, in (mm).
Refer to Figure 15.

Figure 15 - Wormgear face width
5.9.14 Wormgear basic dimensions

The dimensions calculated in Clause 5.3 through Clause 5.9 are illustrated in Figure 16.
6 Modified tooth proportions

The customary proportion design method given in Clause 5 usually results in satisfactory applications
with 2 - 3 wormgear teeth in contact. However, some applications with unique requirements may require
the use of modified tooth proportions.
6.1 High contact ratio designs

The purpose of this design is to obtain a higher contact ratio (more teeth in contact instantaneously). This
in turn provides for averaging thread and tooth variations, where smooth transmission of motion is
required. The design method is to enlarge addendums and dedendums, coupled with the use of low
pressure angles. Both of these modifications increase contact ratio. A check must be made to assure
adequate thread tips and avoidance of undercutting. Due to the greater tooth depths, the wormgear teeth
individually have less strength, but this is somewhat canceled by the increased number of teeth in
contact. Also, the worm root diameter will be smaller for a given worm pitch diameter and both root and
pitch diameters may need to increase in order to support the gearing forces when a high contact ratio
design is used.

Figure 16 - Wormgear basic dimensions - customary proportions
6.2 Stub tooth designs

For high strength applications, the working depth of both the worm and wormgear can be reduced or
stubbed as is done with spur and helical gearing. This modification increases the strength of the
wormgear teeth by reducing the maximum height at which the gear load can be applied, but it also
reduces the contact ratio or number of wormgear teeth in contact at any given time with a resulting
decrease in wormgear durability. Stub tooth designs are used where high static gear tooth strength is
required.
6.3 Recess and approach action

For the customary proportion design method given in Clause 5, the wormgear pitch diameter is at the
middle of the working depth of the wormgear tooth. Contact lines on the wormgear tooth above the pitch
circle are in an approach action mode while the contact lines below the pitch circle are in a recess action
mode (refer to Figure 17). Approach action is to the left of the centerline and the wormgear teeth are
coming into full mesh whereas recess action is to the right of the centerline and the wormgear teeth are
coming out of mesh. Contact in the recess action zone is claimed to result in the following:
– The coefficient of friction of contact in the recess action zone is somewhat less than in the
approach action zone.
– In the recess zone, the normal tooth loads are more tangent to the wormgear, and the direction of
the friction component aids the motion of the wormgear (see Figure 17).
– Contact in the recess zone has a tendency to polish the contacting surfaces.
– For equal worm and wormgear accuracy levels, recess action contact will generally provide less
wear and noise in operation.
– The above definition of recess action is true only when the worm is driving the gear. If the
wormgear is driving the worm, as in an increaser or in reversing service (wheel drives or
elevators), the recess action zone becomes approach action, and the approach action zone
becomes recess.

6.4 Design for additional or full recess action

If the worm is driving the wormgear, which is the usual case, it is sometimes advisable to increase the
amount of recess action occurring in the wormgear mesh. To accomplish this, the actual wormgear pitch
diameter is moved from the mid-depth of the wormgear tooth to the throat or outer diameter of the
wormgear which results in a zero addendum wormgear and long addendum worm.
Figure 17 - Approach and recess action - customary proportions

For zero or long addendum designs, the minimum number of wormgear teeth must be greater than
specified in Table 2, and the tooth combination changed to accomplish this. Table 3 lists the suggested
minimum number of teeth for zero addendum designs. Consideration must also be given to the
relationship between the strength and durability of the wormgear teeth, center distance, ratio, worm
diameter, lead angle, thread profile and tool design based on the loads to be transmitted.
As specified in Clause 5, if the center distance and the ratio are fixed, the worm and wormgear
proportions can be calculated as done in Clause 5 for standard proportions. The axial pitch and lead of
the worm can be increased arbitrarily as follows:
πD
px = (Increase value of D to a maximum of D = Dt ) (27)
NG
L = NW p x (28)
The actual wormgear pitch diameter is increased to the value selected and the actual worm pitch
diameter is:
d 2C − D
= (29)
All other worm and wormgear dimensions remain the same as calculated in Clause 5 except for the
actual worm and wormgear pitch diameters.

Table 3 - Suggested minimum number of wormgear teeth for modified designs

For pressure angle of: Minimum number of wormgear teeth
(zero wormgear addendum)
14.5º 69
17.5º 49
20º 38
22.5º 31
25º 25
27.5º 21
30º 18
Figure 18 shows a nearly all recess action design where the wormgear pitch diameter is made equal to
the wormgear throat diameter. While all or most of the contact will occur in the recess action zone, the
line of action, the number of teeth in contact, and the total length of contact lines may be reduced when
all contact is in the recess action zone. However, if the wormgear is driving the worm, as in lowering a
hoist, the favorable recess action contact becomes all approach action.
6.5 Alternative design for additional or full recess action gearing

For existing designs and tooling, and if the ratio can be increased, additional recess action can be
obtained by using the existing worm and hob but gearing the hobbing machine for 2 - 3 more teeth such
that:
NG px
D= (Increase NG such that D ≤ Dt but > standard D) (30)
π
Refer to Table 3 for the minimum number of teeth for which this can be done.
7 Contact patterns
The lines of contact that move from the wormgear outside diameter to the working depth, sweep out an
area of contact on the wormgear. The initial contact on new wormgear teeth should normally be less than
the full face width of the wormgear and less than the working depth of the wormgear teeth. This allows
for deflection under load, small errors in the axial position of the wormgear, and mounting variations. In
addition, it establishes a gap for entry of lubricant at the gear mesh (see Figure 19).
Figure 18 - Approach and recess action - modified proportions

7.1 Initial contact for power drive wormgearing

Figure 19 shows typical acceptable initial no-load contact patterns that should be obtained by hobbing
and mounting wormgears with a "leaving side” contact. The contact pattern on the driving flanks of the
wormgear teeth is obtained by coating the worm threads with a soft blue dye and rotating the assembled
and shimmed wormgear through the worm threads by hand and observing the transferred blue marking
on the wormgear tooth flanks. These acceptable contact patterns leave an entry gap where the worm
enters the wormgear tooth. The entry gap allows for easy entry of lubricant during initial running of the
gear set, and when the wormgear deflects axially and the worm bends under load, the contact tends to
become more central while still leaving some entry gap for lubricant. When the wormgear is to transmit
load in both directions of rotation, the other drive flank should have a similar "leaving side” contact which
is diagonally opposite the patterns shown in Figure 19 (diagonally opposite because the worm is rotating
in the opposite direction of rotation). Profile variations in both the worm and wormgear may reduce the no
load contact pattern.
7.2 Unacceptable initial contact

Unacceptable wormgear flank contact is shown in Figure 19 and is the worst possible condition under
which a worm and wormgear can be run, since there is no entry gap for lubricant, and deflection may
aggravate the trouble further. A wormgear mounted in this manner may result in a temperature rise in the
lubricant and the wormgearing as much as 20% higher than a properly hobbed and mounted wormgear.
Axial adjustment of the wormgear (by means of shims) to one side by a small amount can result in an
acceptable “leaving side” pattern.
7.3 Mounting and assembly problems and their effects on initial contact patterns
Unlike involute helical or spur gearing, wormgear contact is affected by the mounting center distance. A
few thousandths of an inch increase in center distance will cause the initial wormgear contact to move to
the leaving side and a decrease in center distance will move the wormgear contact to the “entering side.”
This is particularly true for the 3 - 15 ratios and less so for the 50 - 100 ratio designs. In addition, the
angularity of the housing bores can have an effect on the gear contact. Most wormgearing can
accommodate housing angularity held to 90° + 5 arc minutes but there will be some variation in contact
patterns, and for highly loaded gearing closer angularity limits should be held.
A typically overlooked mounting problem is wormgear mounting radial and side or face runout. If the
wormgear is mounted on a shaft or on bearings with radial runout or against a shaft shoulder or flange
with axial runout, the initial wormgear contact can vary around the wormgear. To discover this type of
mounting problem, the initial wormgear contact should be checked at three places at 120° around the
gear.
7.4 Other causes of variations in initial contact patterns

The acceptable ranges of contact patterns shown in Figure 19 can vary from wormgear to wormgear or
around the wormgear just depending on the amount of soft blue dye used. The main concern is to have
the general location of the contact area on the leaving side. A significant variation in contact pattern can
occur from tooth to tooth around the wormgear due to tooth spacing errors, particularly with even ratios.
Every other tooth can vary on a 2-start worm; every third tooth can vary on a 3-start worm, etc. (see
Clause 4.3, Clause 4.6 and Figure 20). Such variations in initial contact pattern are acceptable in most
power drives and the contact will become uniform after some hours of operation.

Figure 19 - Initial no-load wormgear contact
Figure 20 - Initial no-load wormgear contact variations due to wormgear tooth spacing errors
even ratio (40/2 = 20 ratio)
7.5 Wormgear contact under load
While initial wormgear contact under no-load should be on the “leaving side,” when the wormgear is
operated under load for several days the contact should become almost full-face contact to keep the
contact stresses low. When the gearing is operating at low speeds and high torques, initial contact
should be set to the minimum contact areas shown to allow for greater deflections. For gearing operating
at high speeds and low torques, the maximum area of initial no-load contact should be obtained where
possible. In critically loaded gearing, a repositioning of the axial location of the wormgear after 200 - 500
hours of operating can be done to obtain nearly full-face contact under actual loads being transmitted. In
this first 200 - 500 hours of operation, some wormgear pitting and wear usually occur while the wormgear
teeth are “worn-in” to suit the actual loads being transmitted.
7.6 Special initial wormgear contact

For certain applications of power drives, it is advantageous to have central contact on the wormgear
teeth. This initial contact is shown in Figure 21.

Figure 21 - Special initial no-load wormgear contact

It can be produced by cutting the wormgear with oversize hobs. The amount of entering and leaving gap
is such that full-face contact is usually not obtained even after many hours of running, but satisfactory
wormgear life results even at AGMA rated loads. It is particularly advantageous to have central contact
for applications where the wormgear drives the worm (speed increasers) or for reversing drives, where at
times the wormgear drives the worm (hoists, cranes, wheel drives, elevators). In situations where the
wormgear drives the worm, the normal “leaving side” contact shown in Figure 19 becomes entering side
contact. Thus, the need for central contact.
The techniques for producing "central” contact on wormgearing have been developed by the
manufacturers who should be contacted for more details if necessary.
8 Run-in procedures
The running-in of wormgearing immediately after installation of new gearing may not always be
necessary, but to do so is certainly advantageous.
8.1 Definition of run-in

When the gearing is correctly designed for its load conditions, there is no difficulty if its full load is applied
from the start. The gearing is designed to carry its specified load without showing signs of failure or need
of replacement. There are advantages to be gained from an initial running under part load, followed by a
gradual build-up to full load.
8.2 Results of run-in

No matter how well finished wormgearing surfaces may be from the machining operations, they do
require some time to smooth down and to achieve a work hardened surface on the bronze. The gearing
has a better chance of providing maximum performance if the initial working can be done gradually.
8.3 Initial running at full load

An immediate application of full load or overloads, due to new driven equipment, concentrates high
contact pressures on small areas which may cause some temporary damage to the surfaces and may
cause high local surface temperatures. There are instances where a heavy overload during initial running
has been known to cause lasting damage to the very hard worm thread surfaces. The temporary damage
to the wormgear bronze surfaces will often "heal” after continued running at full or less than full load. The
run-in of wormgearing at gradually increasing loads can prevent the occurrence of such surface damage.
8.4 Initial friction at the mesh

Experience of testing and running of wormgearing indicates that the initial friction is about 15% higher
than that which will be obtained after run-in is completed. The first few hours of operation at gradually

increasing loads reduces the friction and the efficiency settles down to a steady figure after about 10 -100
hours of operation, depending on the size and speed of the gearing.
8.5 Recommended run-in period

A reasonable run-in procedure is to apply approximately one-half load for a few hours and then to
increase the load in at least two stages, if possible.
8.6 Wormgear pitting

The surface damage occurring during initial running, whether at full load or reduced load, and described
in Clause 8.3 may result in scattered corrective pitting on the wormgear tooth surfaces after 500 - 1000
hours of additional operation. The presence of such pitting in some applications is often of concern.
However, laboratory load testing of even extensively pitted bronze wormgears have shown that accuracy
of motion transmission, gearing efficiency, noise level, load capacity and the heat generated is not
significantly affected by the presence of such pitting.
9 Rating and efficiency

The rating and efficiency formulas contained in AGMA 6034-B92, Practice for Enclosed Cylindrical
Wormgear Speed Reducers and Gearmotors, are applicable to wormgear sets designed in accordance
with this standard.
Parametric dimensionless equations exist for expressing the efficiency with the worm driving and with the
wormgear driving.
Worm driving efficiency:
(cos φ n − µ tan λ m )
ηw = (31)
(cos φ n + µ cot λ m )
Wormgear driving efficiency:

(cos φ n − µ cot λ m )
ηg = (32)
(cos φ n + µ tan λ m )
where
ηw is the worm driving efficiency;
ηg is the wormgear driving efficiency;
λm is the lead angle of the worm at mean diameter;
φn is the normal pressure angle;
µ is the coefficient of friction (from AGMA 6034-B92).
To assure that the wormgear will drive the worm in the static condition;
µ static < cos φ n tan λ m (33)
where
µ static is the static coefficient of friction (from AGMA 6034-B92).
To prevent the wormgear from driving the worm, refer to clause 9 of AGMA 6034-B92 for a discussion of
self-locking in the static condition.

10 Wormgear blank design

Good wormgear design is greatly dependent on proper wormgear blank design. The blank must provide
proper support of the wormgear teeth and withstand the tangential, separating and axial forces applied by
the worm threads during operation and by the hob during tooth cutting. Excessive deflection of the rim of
the blank along its axis can cause the wormgear contact to continually shift under heavy or varying torque
loads.
10.1 Typical wormgear blank configuration

Figure 22 shows typical blank designs. It is recommended that not less than one times the tooth height
(ht) be used as the minimum material under the root of the teeth. For heavy shock load applications, this
should be increased to 1.5 times tooth height (ht). For composite construction, adequate mechanical
strength must be assured through proper sizing and number of bolts, dowels, set screws or welds.
Configurations 3 and 4 require special consideration during the casting process to assure that a proper
bond has been achieved and that no excessive tensile stresses remain in the bronze rim which could lead
to failure.
10.2 Wormgear web configuration

For small wormgear blanks, no separate web section may exist, especially if the hub is of relatively large
diameter. In cases where a wormgear web is a significant portion of the overall size, the use of a conical
configuration should be considered (refer to Figure 22 configuration number 1). This design will add axial
stiffness to the wormgear blank and it also results in reduced internal stresses during the casting process.
10.3 Wormgear hub design

The most common hub configuration for small wormgear drives using a solid output shaft is a hub width
of about 1.2 to 1.5 times the shaft diameter. The medium press fit between shaft and wormgear bore is
typically 0.0005 inch per inch of shaft diameter. Usually a single key or Woodruff key is used for torque
transfer, although multiple keys or splines are occasionally used. Cross sectional area, especially in the
key area, must be sufficient to support operating and shock loads. For shaft and key stress values,
consult AGMA 6001-F19, Design and Selection of Components for Enclosed Gear Drives.
11 Worm manufacturing practices

Various machining methods can be used to produce the various thread profiles on worm shafts. The
particular method used depends on the loads to be transmitted and the transmission accuracy required.
11.1 Worm thread milling

In thread milling, a thread milling machine is used. It is basically a screw cutting lathe designed
specifically for the production of single or multiple threads. A single form rotary milling cutter has one row
of teeth. The cutter axis is tilted to the mean lead angle of the thread and is fed radially inward to the full
thread depth with the worm kept stationary, at which time the worm is rotated slowly with the cutter
simultaneously being moved parallel to the worm axis until the desired number of thread wraps are
obtained. For multiple threaded worms, this process is repeated after indexing the worm until all the
threads have been formed.

Figure 22 - Typical wormgear blank configuration minimum rim thickness
11.2 Worm thread milling with multiple milling cutters

Worms with very small lead angles can be milled faster by using multiple form milling cutters having
several rows of teeth having no lead. The rows of teeth are spaced axially one axial pitch apart. The
cutter axis is set parallel to that of the worm. With the worm stationary, the cutter is fed inward to the
desired thread depth. The worm then is rotated slowly with the rotating cutter being moved
simultaneously on an axis parallel to that of the worm according to the thread lead. The thread is
complete when the worm has rotated slightly more than one revolution.
11.3 Worm thread hobbing

Thread hobbing is generally preferred when multiple thread worms are to be produced. The hobbing
machine is set up as is done for hobbing a helical gear except that a 90° hob swivel may be required for
worms with low lead angles (high helix angles) and different calculations are made for the index and feed
gear trains. When using hobs to produce multiple threads, it is unnecessary to index each thread as in
thread milling. The hob develops the indexing automatically. The surface finish of the threads is a
function of the number of gashes in the hob. The more gashes, the better the surface finish. For this
reason, this type of hob is made as large as possible to allow a maximum number of gashes.
11.4 Worm thread generating with a shaper cutter

Thread generating with a shaper cutter permits the cutting of single or multiple thread worms in one
continuous cutting cycle. Such a thread generating machine makes use of a helical type gear shaper
cutter whose axis, when mounted, is at right angles to the worm axis. The cutter generates the threads
as it rotates in mesh with the worm while translating in a direction parallel to the worm axis.
11.5 Worm thread rolling

The most economical method for threading worms in mass production is thread rolling. In this cold
forming process the worm is threaded while being rolled between two driven, horizontally mounted,
cylindrical rolling dies while being supported on the bottom by a hardened steel rest bar. Hydraulic
pressure is used to feed one die inward to a preset depth. The dies, much larger in diameter than the
worm, have hardened and ground threads and a pitch diameter that is a multiple of the worm being rolled.
Because of their size, the dies are made with multiple threads to obtain the same lead angle as the worm.
Since metal is displaced rather than removed to form the threads on the worm, accurate and smaller
outside diameter worm blanks are required to produce consistently accurate worms.

11.6 Worm thread grinding

Thread grinding is used to produce very accurate threads on worms that have been roughed out by one
of the processes discussed in Clause 11.1 to Clause 11.5. Grinding is required to remove distortions
present after the threads are hardened. This process is similar to thread milling described in Clause 11.1,
except the milling cutter is replaced by a shaped grinding wheel that has been either diamond or crush
dressed. The grinding wheel is usually tilted to the mean lead angle of the worm (refer to Clause 4 for
thread profiles). Grinding wheel speeds are much higher than milling cutter speeds. Several grinding
passes may be required, depending on the hardening method, stock allowed and heat treating distortions
present.
12 Wormgear manufacturing practices

The teeth of wormgears are generated by a process known as hobbing using either a hob or flytool (see
Figure 23).
Figure 23 - Generation of wormgear teeth
12.1 Wormgear hobs

Hobs for cutting wormgears must have approximately the same diameter as the worm that will mate with
the wormgear and are similar in appearance to the worm except the threads are fluted or gashed to form
cutting edges. Because the hob is reduced in diameter each time it is sharpened, a new hob is designed
with radial oversize in order to allow for several sharpenings.
12.2 Wormgear hob design

The details of hob design cannot be fully discussed in this manual and can be left to the hob
manufacturer, but the user of the hob must ensure that the hob manufacturer is aware of the initial
contact requirements of the wormgear, the thread shape of the mating worm, and the type hob to be
used.
12.2.1 Hob oversize

As discussed in Clause 7, initial contact requirements depend upon the ratio being hobbed, the
deflections and loads involved, and the type of service the wormgear is to undergo. The initial contact
obtained depends heavily on the amount of hob radial oversize specified. The more oversize used, the
more crowning of the wormgear teeth and the less contact. Very little oversize will produce a very full
face contact. The amount of oversize is a compromise between initial contact requirements and hob life.
12.2.2 Hob profile

Hobs must be produced with the same profile as the mating worm to assure proper conjugate action (see
Clause 4.5).

12.2.3 Type of wormgear hob

Wormgears can be hobbed by either feeding the hob tangentially past the wormgear blank or radially into
the blank (see Figure 24).
When the thread lead angle is over 15° or a large number of threads are involved, the tangential hobbing
method should be used to achieve the best wormgear accuracy. In this method, the hob is fed in a
direction tangent to the pitch diameter of the wormgear being hobbed. A tangential hob is tapered along
its axis. Its entry end provides roughing teeth which remove most of the material. Several rows of
finishing teeth are provided at the exit end of the hob to generate the final accurate tooth shape. In radial
feed hobbing, also called infeed hobbing, a cylindrical hob with finishing teeth along its entire length is fed
radially into the gear blank with no axial feed. In-feeding is used most successfully when the wormgear
teeth have less than 15° lead angle and the mating worm has few threads. Because radial feed distances
are less than tangential feed distances, in-feed hobbing has a lower production cost. Factors affecting
the selection of tangential or infeed hobbing include the quality required, cost and the type of hobbing
machine available.
12.3 Wormgear flyhobbing

Where small quantities of wormgears are to be hobbed, the manufacture of a hob is usually not
economical. In this case, a single point tool which has the equivalent form and size as the finishing teeth
on what would be a tangential hob can be mounted in an arbor in the hob spindle of the hobbing machine.
This flytool can then be slowly fed tangentially through the wormgear blank to generate the wormgear
teeth (see Figure 25).
Infeeding or radial feeding of such a single point tool will not generate the wormgear teeth fully so the tool
must be tangentially fed. All of the teeth will be generated on single start designs but multiple start ratios
must be hunting tooth in order to form all the teeth with the single point (thread) flycutter. Even ratios as
discussed in Clause 4.3 cannot be generated accurately in one cycle by the single point flycutter method.
Aside from lower tool cost, the flycutter method has the advantage of allowing the use of zero or small
amounts of radial oversize since the tool can be set after each sharpening to the same design diameter
(see Figure 25).
Depending on the tangential feed rates used, and the amount of radial oversize selected, required
wormgear tooth accuracy and initial contact may be more easily obtained with a flycutter than a hob.
13 Materials and heat treatment

The materials used for wormgearing are similar to those used for journal or sleeve bearings. The rating
formulas given in AGMA 6034-B92 apply for a steel worm hardened to HRc 58-62 running on a bronze
wormgear.

Figure 24 - Hobbing of wormgears
Figure 25 - Flytool hobbing of wormgears
13.1 Worm materials

Worm threads should be hardened (HRc 58-62) and have a 16 micro-inch (0.4 µm) surface finish RA.
The shape of the threads usually changes very little throughout the life of the gear set. Steel worms are
typically manufactured with the threads roughed or finish formed from low carbon carburizing grades such
as AISI 1020, 1117, 8620, or 4320. The threads are then carburized and hardened to provide a case
hardness of HRc 58-62 and the desired core hardness for the grade of steel selected. A minimum
effective case depth of 0.035 px + 0.010 is recommended for carburized worms (total case depth is
approximately 1.5 times the minimum effective case depth). These minimum values refer to the finished
worm after grinding and not to the preground thread.

Worms are also produced using medium carbon steels, such as AISI 4140 or 4150, which are induction
or flame hardened to produce a surface hardness of HRc 58-62. The desired core hardness is obtained
by specifying the hardness of the through hardened bar or forging used. Finishing after either of these
heat treating methods is by grinding if heat treating distortions cannot be tolerated. Finishing is
sometimes done by polishing alone if heat treating distortions can be controlled. Worm sets using worms
made from soft cast iron, ductile iron or steel, through hardened steel (HBW 300), or worms hardened to
intermediate hardnesses (HRc 50) can be used if lower loads than AGMA 6034-B92 ratings are involved
and an analysis of worm surface and bending stresses is made (see Clause 15.3).
13.2 Wormgear materials

The wormgear material should be soft and compliant enough to run-in successfully, have good bearing
qualities, and yet be able to give good service life after run-in.
13.2.1 Phosphor bronze

If significant amounts of power are involved, a phosphor or tin bronze is usually employed. This material
is copper with 9-13% tin, 0.10-0.13% phosphorous, and occasionally 1-1.5% nickel which is either sand,
chill or centrifugally cast (see AGMA 6034-B92). Finer grained and stronger wormgears can be produced
using the chill casting or centrifugal casting methods, particularly for larger wormgears (over 3.5 inch
[88.9 mm] center distance).
13.2.2 Manganese bronze

Where rubbing speeds are less than 1000 ft/min (5.08 m/s) and the wormgears are small (up to 3.5-inch
(88.9 mm) center distance), forged manganese bronze (strictly speaking a brass) is often used. This
material is copper with 28-38% zinc and 2-3.5% manganese and is forged and heat treated to obtain its
proper microstructure.
13.2.3 Alternate wormgear materials

For lightly loaded motion transmission wormgearing, the wormgear material may be cast iron, ductile iron,
soft steel or various grades of plastic. When high torques at low speeds (less than 500 ft/min (2.54 m/s) )
are involved, wormgear materials such as high strength aluminum bronzes (CDA 954000 for example) or
manganese bronzes (CDA 86300 for example) are used to provide high wormgear tooth bending
strengths. Since these bronzes are reasonably hard and will not easily conform to the worm during run-
in, a fuller initial wormgear contact than described in clause 7 may be desired.
14 Lubrication
Lubricants are introduced into the worm and wormgear mesh to reduce friction and heat and to prevent
metal-to-metal contact, thereby reducing or eliminating wear.
14.1 Regimes of lubrication

Lubrication conditions at a wormgear mesh can be metal-to-metal, boundary, full film, or a combination of
the three depending on the loads being transmitted and the lubricant being used.
14.1.1 Metal-to-metal
With high torques, low speeds, and low lubricant viscosity, metal-to-metal contact can result.
14.1.2 Boundary lubrication

If lubricant viscosity is high and mesh contact pressures are lower, boundary or mixed lubrication may
exist where a partial or very thin hydrodynamic film is developed.

14.1.3 Full film lubrication

With higher speeds and high viscosity lubricants, a full film or hydrodynamic film of oil is developed which
prevents metal-to-metal contact.
14.2 Mineral oils

The usual wormgear lubricant recommended is a high quality petroleum based oil blended with 3-10% of
acidless tallow and rust- and oxidation-inhibiting additives. These compounded gear oils are specified in
ANSI/AGMA 6034-B92 and AGMA 9005-F16 [1] and are suitable for most applications where the ambient
temperature range is 15 to 125°F (-10 to 52°C).
14.3 Synthetic oils

The use of specific polyglycol or polyalphaolefin based gear oils can provide additional performance
features over the compounded mineral oil. These include wider application temperature range, longer oil
life and improved gearbox efficiency. However, at this time, these benefits for wormgears are not well
specified and specific data supporting the potential added benefits should be obtained from the synthetic
oil supplier.
14.4 Splash lubrication

Splash lubrication by rotation of the worm or wormgear in the reducer oil reservoir is usually sufficient to
get lubricant to the mesh and to carry away the heat generated.
14.4.1 Oil level

With the worm located below the wormgear, the “at rest” oil level should be at the centerline of the worm;
however, when speeds are low, an oil level above the worm and wormgear mesh may be required. When
the worm is located over the wormgear, an oil level such that one-third of the wormgear diameter dips in
the oil reservoir is usual, although if the worm speed is less than 400 rpm, the oil level should be raised
so that the worm and wormgear mesh is under oil. Vertical input or output shafts usually have the oil
level set at the wormgear mesh point with a shielded or grease lubricated upper bearing.
14.4.2 Oil fill, vent, level and drain

The oil fill plug should be above the oil level plug and may be a combination fill plug and air vent. The air
vent should be located so that it does not receive direct oil splash, or it should be internally baffled so that
oil is not carried out the vent when internal pressure is relieved. It is recommended that at least 10-15%
of the space in the reducer be airspace. Oil sight gages or oil level plugs should be placed at the desired
level and should be properly labeled.
14.5 Forced feed lubrication

This special provision is used for larger units where the worm speed is high (over 2000 ft/min [10 m/sec])
or whenever external cooling of the oil must be done.
14.5.1 Location of spray nozzles

If a forced feed lubrication system is employed because of high worm speeds, spray nozzles should
lubricate the mesh on both sides of the wormgear and the bearings if needed. Generally, a flow rate of
1/2 to 1 gal/min (2 to 4 l/min) per inch of gear face is adequate for the wormgear mesh. The bearings
may require 0.1 gal/min (0.4 l/min) per inch of bearing bore, depending on the type of bearing and the
speeds. Care should be taken to allow for drainage of the sprayed lubricant back to the oil reservoir.
Sump capacity and pump rate should be large enough that there is sufficient dwell time to allow for foam
dispersal.
14.5.2 Forced feed lubrication with cooling

When the lubrication system is required to provide external cooling of the oil, the heat to be dissipated is
the sum of the wormgear mesh losses determined by the efficiency calculation in ANSI/AGMA 6034-B92,

the bearing losses, and the seal drag. Bearing and seal manufacturers can calculate these losses given
the lubricant operating viscosity and the bearing loads and shaft speeds. The lubrication system
elements are discussed in the following paragraphs.
14.5.2.1 Sump
The oil sump capacity should be 1.5-2 times the flow rate in volume per minute.
14.5.2.2 Strainer or filter

Depending on the pump used, a simple intake strainer to remove the larger or coarser particles or an
inline filter to remove finer particles is required.
14.5.2.3 Oil pump

Either a positive displacement or centrifugal pump can be used. A positive displacement pump is
preferred since priming is simplified. The flow rate must be sufficient to provide adequate lubrication and
to dissipate the heat generated.
14.5.2.4 Heat exchanger

A water- or air-cooled heat exchanger is usually used to dissipate the heat. Optionally, an oil temperature
control valve can be used to vary the amount of water or air directed to the heat exchanger.
14.5.2.5 Oil pump driver

The oil pump may be driven by its own electric motor. The motor must be sized based on the power
required to pump the oil during start-up when the oil is heavy, and the line and other component pressure
losses are at maximum levels. Alternately, the pump can be driven from an unused end of the worm shaft
or the wormgear shaft.
14.5.2.6 Relief valve

To bypass clogged lines or inadvertently shut off filters or other components, a relief valve and line back
to the sump is required at the discharge of the pump.
15 Analysis of gearing forces, worm bending stress and deflection

Gearing forces between the worm and wormgear exist which must be analyzed to assure adequate worm
diameter (see Clause 5.9.6), to calculate housing and bolting stresses, and to calculate bearing loads and
life.
15.1 Tangential, separating and thrust forces

A wormgear shaft transmitting power is subject to reaction loads at the mesh as shown in Figure 26.
These forces are assumed to act at the pitch point of the mesh.
15.1.1 Wormgear tangential force

This component of mesh force is determined as follows:
2TG
Wtg
= = Waw (34)
Dm
where
Wtg is the wormgear tangential force, lbs (N);
TG is the wormgear torque, lb-in (Nm);
Waw is the worm thrust force, lbs (N);

2000TG
Wtg
= = Waw (34M)
Dm
Dm is the wormgear mean diameter, in (mm).
and
D=
m d m + 2C
15.1.2 Separating force

The mesh separating force is:
Wtg tan φ n
=Wsg = Wsw (35)
cos λ m
where:
Wsg is the wormgear separation force, lbs (N);
Wsw is the worm separating force, lbs (N).
15.1.3 Wormgear thrust force

The wormgear thrust force may be obtained from the worm torque as follows:
2Tw
W
=ag = Wtw (36)
dm
where
Wag is the wormgear thrust force, lbs (N);
Wtw is the worm tangential force, lbs (N);
Tw is the worm torque, lb-in (Nm).
15.2 Worm bearing reactions

Referring to Figure 27, the wormgearing reactions can be used to determine worm bearing loads as
follows:
2 2
W A W d  W A 
RA =  sw + aw m  +  tw  (37)
 l 2l   l 
2 2
 Wsw (l − A) Waw d m   Wtw (l − A) 
RB
=  − + (38)
 l 2l   l 


Figure 26 - Worm and wormgear forces - RH thread

where
RA is the bearing A radial load, lbs (N);
RB is the bearing B radial load, lbs (N);
l is the bearing span, in (mm);
A is the distance from pitch point to bearing B, in (mm).
15.3 Worm bending stress

Knowing the bearing reactions, a conservative value of the worm bending stress can be determined by
considering the worm as having a diameter equal to the worm root diameter(refer to Figure 27).
M = RB ( A) or=
M RA (l − A) (39)
whichever is greater
RB ( A) RA (l − A)
M= or M = (39M)
1000 1000
whichever is greater
where
M is the worm bending moment, lb-in (Nm).
32 M
Sb = (40)
π d r3
32000 M
Sb = (40M)
π d r3
where
Sb is the worm bending stress, lbs/in2 (N/mm2);
M is the worm bending moment, lb-in (Nm).
15.4 Allowable worm bending stress

The worm bending stress calculated by the above method must be less than 17% of the ultimate tensile
strength of the worm core material for the normal running torque of the gear set, and 75% of the yield
strength of the worm core material for maximum momentary overload torques which the gear set must
withstand. These allowable stress levels are conservative values that reflect the usual stress
concentration factor and torsion stresses present in the worm threaded area. For the definition of

momentary overload, refer to Clause 7.4 of ANSI/AGMA 6034-B92. If calculated worm bending stresses
exceed the allowable values, the worm design must be revised to provide a larger worm root diameter or
a smaller pressure angle.
Figure 27 - Worm bearing reactions
15.5 Worm deflection

A conservative and approximate value of worm deflection can be determined by using the equivalent
beam method described below (refer to Figure 28).
Figure 28 - Equivalent beam for worm
15.5.1 Equations for determining worm deflection

F RA + RB
= (41)
where
F is the equivalent load, lbs (N).
RA
k= (42)
F
where
k is the location factor of equivalent load.
3
Fl 3  2k k 2  2
y= (1 − k )  −  (43)
3EI  3 3 

where
y is the worm deflection, in (mm);
E is the modulus of elasticity, lb/in2 (N/mm2);= 30 000 000 lbs/in2 for steel= 206 850 N/mm2
for steel.
π d r4
I= (44)
64
where
I is the moment of inertia, in4 (mm4).
15.5.2 Allowable worm deflection

For normal running loads, the maximum allowable deflection of the worm shaft must be less than
( )
.005 p x in 0.025 p x mm , where px is the axial pitch of the worm, as specified in AGMA 6034-B92. This
allowable worm deflection limits the amount of worm and gear contact shift to acceptable values. If
calculated worm deflection exceeds the allowable value, a more detailed analysis is required, or the worm
design must be revised to provide a larger worm root diameter or a smaller pressure angle.
16 Assembly procedures
The performance capability that is designed and manufactured into a wormgear set can only be achieved
by the correct mounting of the wormgear set in the assembly. To achieve the correct mounting, the worm
and wormgear must be located laterally, vertically, axially, and at the required shaft angle to provide tooth
contact pattern and backlash to the design specifications.
16.1 The housing

The housing provides worm and wormgear lateral, vertical, and angular position. The end caps
associated with the housing provide the axial position of the gear elements.
To achieve the expected performance of a wormgear set, the same care that goes into the design of the
worm, worm blanks and the wormgear elements should be exercised in the design of the housing. The
worm and wormgear mountings must be designed to have adequate support for worm and wormgears for
all load conditions to which the wormgear set may be subjected. Each member of the wormgear set
should be restrained against lateral, vertical, axial and angular displacement. Excessive misalignment
reduces the load carrying capacity of the wormgear set, with consequent danger of premature element
failure. Consideration must be given to the alignment of opposing bearing seats relative to concentricity
of one another, angular and vertical position relative to the mating gear element axis. Bearing mountings
associated with end caps that are supported by the housing must be designed considering the effect of
the end cap fit to the housing with respect to maintaining gear element lateral, vertical and angular
positions, relative to the mating gear element axis.
16.2 Position tolerance

In the assembly of a worm and wormgear, customarily the only controllable adjustment is the axial
position of the worm and wormgear. Most successful designs provide a means of shimming or other
methods for positively locating the axial position of the gear elements.
The axial position of the worm provides the greatest amount of position tolerance. The worm must be
positioned and restrained axially to provide a full thread at the point of initial and final wormgear contact
with the worm. The worm should be designed with sufficient worm face width to allow for liberal axial
positioning of the worm.
Precise axial position and restraint of the wormgear is necessary to provide the desired system backlash
and contact pattern of the wormgear set. The axial positioning is generally accomplished by the
capability to shim both bearing axial retention positions of the wormgear axis to compensate for the effect

of maximum tolerance accumulation of the components. The wormgear must be axially positioned to
result in the wormgear being centrally located on the worm. The desired position is determined by
achieving the assembled wormgear set backlash and contact pattern.
16.3 Contact pattern check

The wormgear contact pattern is a visual determination of the wormgear axial location to achieve the
desired position of the gear element and provide the initial contact pattern to carry the design load on the
gear element profiles and allow for an oil entry gap.
Acceptable wormgear contact patterns are illustrated in Clause 7.
The contact pattern should be uniform on all wormgear teeth and determined at no load conditions.
16.4 Backlash check

Backlash is required in a wormgear set to allow for thermal expansion of the wormgear without
interference.
Backlash should be kept to a minimum in the design of the assembled wormgear set to minimize dynamic
loading to the wormgear teeth and worm threads in load reversal applications. The backlash will slightly
increase from the initial backlash achieved during assembly to the final backlash after the wormgear
profile has developed to match the worm thread during run-in.
Backlash is commonly measured by holding the worm stationary and rotating the wormgear in both
directions. The movement is registered by a dial indicator having its pointer in the plane of rotation at or
near the wormgear pitch diameter and parallel to a tangent to the pitch circle of the wormgear. If the
housing does not allow for direct measurement on the wormgear, a measurement fixture with an indicator
location equal to the wormgear pitch diameter can be locked to the wormgear shaft as an alternative
measuring device. Measurements of backlash may vary in the same gear set, depending on the accuracy
of manufacturing and assembly. Incorrect tooth profiles will cause a change in backlash at different
phases of tooth action. Runout of the worm and wormgear assemblies may cause substantial difference
between the minimum and maximum backlash at different positions. The specified assembled backlash of
the wormgear set should take these elements into consideration.
16.5 End play check

End play in the worm and wormgear axis is generally present after final assembly of the wormgear set.
The end play allows for axial component thermal expansion of the gear element assemblies with respect
to the housing, due to the temperature changes from ambient to operating temperature, preventing
excessive bearing preload.
Assembled end play in both gear element axes should be kept to minimum values. Gear elements
supported by tapered or spherical roller bearings will have radial play associated with end play, which
must be considered in the design and assembly of the wormgear set, relative to their effect during thermal
rise on vertical, lateral, and axial positioning of the gear elements. Ball and cylindrical roller bearings
need only be addressed from an axial gear element position standpoint. Zero end and radial play must
be achieved at full load and operating temperature conditions of the wormgear set.
The design of the housing and associated bearing axial position restraints must provide for end play
adjustment.
End play is checked by positioning a dial indicator at the end of the gear element shaft having its pointer
parallel to the shaft axis. A slight axial force with some oscillation is then applied to the shaft to seat the
bearings in both axial positions to determine the assembled end play.

(informative)
Formulas for worm thread profiles
[The foreword, footnotes, and annexes, if any, are provided for informational purposes only and should
not be construed as a part of AGMA 6022-D19, Design Manual for Cylindrical Wormgearing.]
A.1 Purpose
The purpose of this annex is to provide formulas for finding approximate thread profiles for form ZI and
form ZK.
A.2 Form on involute worm
The amount of form on an involute profile, form ZI, is determined as follows:
d sin φ n
ρ ni = (A.1)
2 sin 2 λ
where
ρni is the radius of normal thread profile ZI, in (mm);
d is the worm pitch diameter, in (mm);
φn is the normal pressure angle of cutter or grinding wheel;
λ is the lead angle at the worm pitch diameter.
Figure A-1 - Radius of normal thread profile ZI

A.3 Form on ZK worm
The amount of form on a worm produced by a straight sided cutter or grinding wheel, form ZK, is
d ρ ni
ρ n =ρ ni + (A.2)
2 R cos 2 λ
where
ρn is the radius of normal thread profile ZK, in (mm);
R is the radius of cutter or grinding wheel, in (mm).

Figure A-2 - Radius of normal thread profile ZK

A.4 Reduction of normal pressure angle
The slight reduction of the normal pressure angle of the thread from the cutter or grinding wheel angle is
as follows:
90 d
∆φ sin 3 λ
N w 2 R cos 2 λ + d
(A.3)
where
∆φ is the reduction in normal pressure angle of worm from the cutter or grinding wheel angle,
degrees.
Figure A-3 - Reduction in thread angle from the cutter or grinding wheel angle - Form ZK

(informative)
Sources of formulas used for determining worm thread profiles
B.1 Purpose
The purpose of this annex is to provide sources of formulas that can be used to find the exact worm
thread profiles for any thread.
B.2 References
The determination of thread shapes produced by known cutter or grinding wheel shapes, or of cutter
shapes required to produce known worm thread shapes, is discussed in a 1943 paper by D. W. Dudley
and H. Poritsky, Cutting and Hobbing Worms and Gears, AGMA P241. The formulas are also contained
in pages 8-15 through 8-20 of the first edition of the Gear Handbook, Darle W. Dudley, Editor, McGraw-
Hill, 1962. Approximate profile formulas are provided in annex A.

(informative)
Sources of information concerning hob design
C.1 Purpose
The purpose of this annex is to provide sources of information concerning hob design.
C.2 References
The following AGMA papers can be referred to for a determination of hob oversize and the resulting initial
contact. Hob profile calculation, number of flutes to be used in the hob, and other hob design
considerations are also covered.
– Allan H. Candee and Anthony Zamis, Oversize of Wormgear Hobs, AGMA P129.09, 1953.
– John R. Colbourne, The Use of Oversize Hobs to Cut Worm Gears, AGMA 89FTM8.
– D. W. Dudley and H. Poritsky, Cutting and Hobbing Worms and Gears, AGMA P241, 1943.
– William L. Janninck, Contact Surface Topology of Worm Gear Teeth, AGMA 87FTM14.
– Ernest Wildhaber, A New Look at Wormgear Hobbing, AGMA P129.10, 1954.
– L. R. Mayo, The Design and Use of Worm Gear Hobs, AGMA P19, 1932.
– Discussion of the Wildhaber Paper, AGMA P129.13, 1954.

(informative)
Worm thread profiles - axial sections
Figure D-1 - Worm thread profiles -- axial sections

(informative)
Bibliography
The following documents are either referenced in the text of AGMA 6022-D19, Standard for Design
Manual for Cylindrical Wormgearing, or indicated for additional information.
[1] ANSI/AGMA 9005-F16, Industrial Gear Lubrication

AGMA 6022 D19 WG

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

AGMA 6022 D19 WG

Uploaded by

Copyright:

Available Formats

ANSI/AGMA 6022-D19

(Revision of ANSI/AGMA 6022-C93)

American National Standard

Standard for Design

American Design Manual for Cylindrical Wormgearing

©AGMA 2019 – All rights reserved i

©AGMA 2019 – All rights reserved ii

6.3 Recess and approach action..................................................................................................... 19

©AGMA 2019 – All rights reserved iii

14.1.3 Full film lubrication ...................................................................................................... 32

©AGMA 2019 – All rights reserved iv

©AGMA 2019 – All rights reserved v

©AGMA 2019 – All rights reserved vi

PERSONNEL of the AGMA Cylindrical Wormgearing Committee

Chairman: Martin Peculis ............................................... Cleveland Gear

Robert Holdsworth ......................................................... Peerless-Winsmith, Inc.

©AGMA 2019 – All rights reserved vii

American National Standard –

Design Manual for Cylindrical Wormgearing

1.1 Uses of wormgearing

1.2 Intended use

3 Symbols and terminology

©AGMA 2019 – All rights reserved 1

Table 1 – Symbols and terms

Symbols Definition Units First used First referenced

©AGMA 2019 – All rights reserved 2

Symbols Definition Units First used First referenced

4 General design considerations

4.1 Characteristics of wormgearing

©AGMA 2019 – All rights reserved 3

Figure 1 - Lines of contact on wormgear teeth

Figure 2 – Relative radii of curvature

©AGMA 2019 – All rights reserved 4

41/2 = 20.5 80/4 = 20-0/4 = 20

4.4 Conjugate action

©AGMA 2019 – All rights reserved 5

4.5 Thread profile of worm

Figure 4 - Rack profiles of worms

4.5.1 Straight sided axial profile - Form ZA

©AGMA 2019 – All rights reserved 6

©AGMA 2019 – All rights reserved 7

4.5.4 Involute helicoid - Form ZI

©AGMA 2019 – All rights reserved 8

Figure 9 - Profile measurement of form ZI

4.5.5 Differences in commonly used profiles

©AGMA 2019 – All rights reserved 9

4.6 Accuracy requirements

4.6.1 Worm accuracy

4.6.2 Gear accuracy

Figure 10 - Tooth spacing accuracy changes - 30 tooth wormgear

©AGMA 2019 – All rights reserved 10

Figure 11 - Tooth spacing accuracy changes - 29 tooth wormgear

5.1 Number of teeth in the wormgear

©AGMA 2019 – All rights reserved 11

5.2 Number of threads in the worm

5.3 Worm pitch diameter

5.4 Wormgear pitch diameter

5.5 Worm axial pitch

©AGMA 2019 – All rights reserved 12

5.6 Worm lead

5.7 Lead angle of the worm

Figure 12 - Variation of lead angle

5.8 Pressure angle