Meshing Theory of Face Worm Gear Drive With Harden 2023 Mechanism and Machin

Mechanism and Machine Theory 185 (2023) 105323
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Mechanism and Machine Theory

journal homepage: www.elsevier.com/locate/mechmt
Meshing theory of face worm gear drive with hardened

cylindrical worm
Shibo Mu a, Yaping Zhao a, b, *, Jian Cui a, Qingxiang Meng c, Gongfa Li d
a
School of Mechanical Engineering and Automation, Northeastern University, Shenyang 110819, P.R. China
b
Key Laboratory of Dynamics Reliability of Mechanical Equipment, Liaoning Province, Northeastern University, Shenyang 110819, P.R. China
c
School of Mechanical Engineering, Yanshan University, Qinhuangdao 066004, PR. China
d
The Key Laboratory of Metallurgical Equipment and Control of Ministry of Education, Wuhan University of Science and Technology, Wuhan
430081, P.R. China
A R T I C L E I N F O A B S T R A C T
Keywords: This article proposes a novel linear contact face worm gear drive. The novel face worm gear drive
Face worm gear consists of a face worm gear and a cylindrical worm enveloped by a tapered surface. The meshing
Offset cylindrical worm drive theory for the novel face worm gear drive is systematically built up. The meshing theory on the
Reference-point-based meshing theory
base of the reference point is further developed aimed at the worm pair where the indexing
Meshing performance
surfaces are planar and cylindrical. The design methods of the rough size for the face worm gear
are introduced. The computing method for the worm limit axial mounting distance is presented
by employing the meshing limit line function. The asymmetry of the tooth surfaces for the worm
pair is evaluated using the helix angle at the midpoint on the line of section for the worm gear
tooth surface and the tooth profile angle for the worm axial section. Numerical results show that
the geometric characteristics and the meshing properties for the tooth surface on both flanks of
the novel face worm gear drive are asymmetrical. However, the meshing properties for the novel
face worm gear drive are satisfactory.
1. Introduction
A novel linear contact face worm gear drive is proposed in this article, as shown in Fig. 1. The novel face worm gear drive may be
attributed to a type of Helicon drive [1] which was invented by Saari from the Illinois Tool Works during the 1960s [2,3]. Refs. [4–6]
investigated the basic design and manufacturing methods of the classical Helicon drives and their characteristics. Litvin et al. [7–10]
studied the existing conditions of the envelopes for the contact lines of the face worm gear pair with intersected axes. They proposed a
mathematical model for the point contact face worm gear drive and provided the error models that help in decreasing the vibration.
Abadjiev [11,12] developed a mathematical model of the pitch contact points and the meshing regions of the classical Helicon drive.
Bolos et al. [13–16] conducted experimental studies on the contact performance and the thermal limit properties for the face worm
gear pair made of different materials.
Unlike the classical Helicon drive [4–6], the worm helicoid for the face worm gear drive proposed in this paper is not an Archi
medean helicoid drawn by a turning (or lathe threading) tool having a rectilinear cutting edge. Instead, it is an envelope surface for the
* Corresponding author: Yaping Zhao, College of Mechanical Engineering and Automation, Northeastern University, No. 11, Lane 3, Wenhua
Road, Heping District, Shenyang 110819, China.
E-mail address: zhyp_neu@163.com (Y. Zhao).
https://doi.org/10.1016/j.mechmachtheory.2023.105323
Received 4 July 2022; Received in revised form 23 February 2023; Accepted 6 March 2023
Available online 16 March 2023
0094-114X/© 2023 Elsevier Ltd. All rights reserved.
S. Mu et al. Mechanism and Machine Theory 185 (2023) 105323
tapered surface of the grinding wheel. From the technical point of view, the Archimedean helicoid of the worm in the classic Helicon
drive is a non-developable surface thus it is impossible to grind using a simple rectilinear profiled grinding wheel. This makes it
impossible to correct the deformations and errors of the worm helicoid after hardening. Thus, the Archimedes worm’s tooth surface
usually has a relatively low hardness [17,18]. Conversely, the helicoid surface of the worm of the novel face worm gear pair one can
apply the precision grinding based on the formation principle to eliminate the deformations and errors after hardening. For this reason,
this novel face worm gear pair is termed a ‘face worm gear pair’ with a hardened cylindrical worm.
The cylindrical worm machined with the tapered grinding wheel can be referred to as the tapered surface enveloped cylindrical
worm [19] or the ZK worm according to DIN standards [7,20]. Wang et al. [21] developed the meshing theory for the classic ZK worm
drive. Litvin [22] introduced the contact and meshing analysis method for the misaligned ZK worm drive. Bair [23] developed the
mathematical model of the dual-lead ZK worm drive. Researchers [24–27] presented several ways to improve the contact performance
for the ZK worm matched with the worm gear machined by a hob having the pitch diameter oversized – hobbing according to the tooth
contact analysis. Liu et al. [28] conducted a simulation study of the non-orthogonal worm drive. Skoczylas et al. [29] studied the
geometry of the ZK worm helicoid formed by the tapered end mill. Deng et al. [30] investigated the high precision machining for the
cylindrical worm drive with large modulus using five-axis machining technology.
In contrast to the cylindrical worm drive, in this paper, the worm is mounted off-set on the worm gear, whose mounting type is very
familiar to the conical worm drive. Therefore, in [1,4], the Helicon drive is considered to be the conical worm pair with a taper angle of
zero for the pinion. Zhao et al. [31–34] carried out in-depth studies of the meshing properties for the conical worm pairs. The studies
show that the conical worm working length covers almost the entire thread length and the contact region runs over virtually the total
worm gear surface. Its local meshing performance is excellent. Besides, this worm drive is also close to the face gear drive in terms of
the mounting type. Scholars [35–38] studied the geometrical model, machining methods, contact analysis, and meshing efficiency for
the face gear drive in a systematic manner. Zhou et al. [39–41] proposed an accurately measured approach to acquire the gear surface
models used in the digitized gear contact analysis and it is further applied in precise and intelligent machining.
In accordance with the meshing theory [42], the meshing property parameters for the worm pair can be determined by its
geometrical characteristics, its relative location in spatial terms, as well as its relative motion. Based on this, theoretically, even though
the novel face worm gear pair proposed in this paper has some characteristics similar to the ZK worm drive like the tapered surface
enveloping the conical worm drive and the face gear drive, their meshing properties are substantially different. Thus, it is necessary to
carry out an in-depth study of the meshing properties of this novel face worm gear drive. For this purpose, this paper systematically
establishes the meshing theory for this novel face worm gear drive. The meshing property parameters can be obtained by the movable
frame built on the worm helicoid.
In addition, a reasonable estimation of the rough dimension for the face worm gear needs to be made before studying the meshing
characteristic for the face worm gear drive. Because the face worm gear pair is classified as an offset gear pair, the relative motion for
the face worm gear and its matching worm is an instantaneous helical motion. If the instantaneous helical axis is rotated around the
axes of each element of the worm pair, a pair of one-sheet hyperboloids results, that is tangent along this. However, it is unfavorable to
manufacture the roughs according to this pair of one-sheet hyperboloids [19]. Thus, Ref. [42] introduced that the rough dimension for
an offset worm drive can be estimated by using the reference cones instead of the one-sheet hyperboloids. Based on this, Refs. [1,7,19]
studied the rough dimension design of the face worm gear pair as if it were a conical worm pair with the cone angle of zero. Illinois Tool
Company [5] has published on its website the design method of the face worm gear pair where the rough dimensions and mounting
dimensions are given according to the specifications.
As described in Ref. [19], the roughs for the conical worm pair are designed according to the indexing cones. However, the indexing
surfaces of a face worm gear pair are the cylindrical surface and plane. This illustrates that the geometry for a face worm gear is simpler
than a conical worm gear. Moreover, this essential difference can lead to the singularity that the denominators of some formulas may
be equal to zero when calculating the geometric arguments for a reference cone pair using the meshing theory on the base of the
reference point [42]. This calls for further development of the existing meshing theory. Thus, in this paper, the reference point is
strictly limited to the worm helicoid using the meshing equation and the worm boundary equations are established based on this. The
limit worm axial installation distance for the novel face worm gear drive can be derived by employing the meshing limit line function.
Fig. 1. Schematic diagram for face worm gear and matched cylindrical worm.
2
Using the characteristic that the indexing surfaces are cylindrical and planar, a new and simpler method for estimating the rough
dimension for the face worm gear pair is presented.
On the other hand, since the worm tooth surfaces are machined by different tapered grinding wheels at unequal mounting angles,
both flanks for the worm helicoids are asymmetrical. Thus, the face worm gear machined using the cylindrical hob consistent with the
worm helicoid is also asymmetrical on both flanks of one tooth. To evaluate this asymmetry, the use of the limit pressure angle is
proposed in Refs. [19,42] as an assessed parameter. However, this assessed parameter is put forward for the conical worm drive whose
indexing surface is the tapered surface. Whether this assessed parameter can be applied to the face worm gear drive whose indexing
surfaces are the cylindrical surface and plane is open to discussion. Thus, two different methods for evaluating asymmetry are sug
gested for the characteristic that the indexing surfaces are the cylindrical surface and plane. This includes that it is brought up to
evaluate the asymmetry of both flanks for the worm helicoid using the tooth profile angle at the worm axial section. Besides, from the
characteristic that the indexing surface is planar, it is proposed to use the helix angle at the midpoint of the line of section between the
indexing plane and its tooth surface to evaluate the asymmetry of both flanks for one tooth on a face worm gear.
Finally, based on these above studies the macroscopic meshing performances for this novel face worm gear pair are discussed by the
numerical examples. The elimination method [31] is applied to convert the non-linear system of equations with four unknowns
encountered in this paper into a single-parameter equivalent form for the iterative solution. The outcomes for the induced principal
curvatures and the sliding angles are graphed as the color nephogram on the worm helicoid and the face worm gear tooth surface to
visualize and reflect the microscopic meshing quality.
2. Grinding engagement of tapered surface enveloping cylindrical worm
2.1. Establishment of coordinate systems
This section uses a right-handed worm for an instance to describe the grinding engagement when machining the worm employing
the tapered grinding wheel. To ensure the meshing quality, two flanks for the worm helicoid are processed by the tapered grinding
wheels at various taper angles [21]. According to Fig. 1, the flank of the worm helicoid which engages the convex flank for the worm
gear can be specified to be the i-flank. The grinding wheel used to process the worm i-flank can be appointed as the No. 1 grinding
wheel. On the other hand, the flank of the worm helicoid which engages the concave flank for the worm gear can be indicated to be the
e-flank. The grinding wheel to machine the worm e-flank is assigned to the No. 2 grinding wheel.
→ → →
To describe the grinding engagement, a stationary orthogonal frame σ o1 {O1 ; i o1 , j o1 , k o1 } is attached to the worm, as illustrated
→ → →
in Fig. 2. The plane O1 − j o1 k o1 is horizontal and the unit vector k o1 overlaps the worm axis. The original point O1 is situated at the
→
midpoint for the worm thread length. When grinding, the rough rotates about its axis k 1 . Its angular velocity vector is noted as → ω.
̅̅̅ ̅→
To acquire the right-handed worm, the tapered grinding wheel will take a translating motion in the direction of Ood Od which is
→ → → →
parallel to k o1 . Thereupon, a rotary orthogonal frame σ 1 {O1 ; i 1 , j 1 , k 1 } is created to represent the current location for the worm
̅̅̅ ̅→ →
rough, whose rotary angle is denoted as φ. The minimum length between the linear vector Ood Od and the unit vector k 1 is the distance
̅̅̅̅→ ̅̅̅̅→ → ̅̅̅̅→
of the straight segment |Ood O1 |. The vector Ood O1 is parallel to the vector j o1 and its length |Ood O1 | is called the technical center
̅̅̅ ̅→
distance which is denoted as ad . At the present location shown in Fig. 2, the straight segment |Ood Od | = pφ, in which the sign p stands
for the worm helical parameter.
Before machining, the tapered grinding wheel needs to be rotated twice to arrive at the assigned installation location which is
→ → →
illustrated in Figs. 2 and 3(a). Thus, the stationary orthogonal frame σ od {Od ; i od , j od , k od } is first built. The origin Od is the center of
→ →
the larger circle of the tapered grinding wheel. k od fits the axis of rotation of the grinding wheel. The angle of the axial line k od with
→ →
the plane O1 − j o1 k o1 is the first worm deflection angle denoted as γ. The deflection angle γ is the same as the lead angle for the worm
Fig. 2. Coordinate systems for relative movement between worm and tapered grinding wheel.
3
Fig. 3. Coordinate systems on tapered grinding wheel.
→
indexing circle. Next, the grinding wheel is deflected around the vector i od by an angle εs , which can be called the second deflection
→ → →
angle. Thereupon, a stationary orthogonal frame σ d {Od ; i d , j d , k d } is created to illustrate the mounting location for the grinding
wheel after the second deflection. Herein, when the symbol S = 1 of the angle εs , it means the deflection angle during machining the i-
flank. Besides, when the symbol S = 2, it denotes the deflection angle during the machining of the e-flank.
→
As shown in Figs. 2 and 3(b), to represent the geometry for the tapered grinding wheel, a stationary orthogonal frame σa {Oa ; i a ,
→ → →
j a , k a } is built at the tapered grinding wheel. The origin Oa is placed on the apex of the cone. k a is situated at the axial line for the
cone and its direction points from the origin Oa towards the origin Od . Fig. 3(b) illustrates the relationship between the frames σ a and
→ → → → → →
σd . During processing i-flank, the position relationship between σ a and σd is i a = j d , j a = i d and k a = − k d . When grinding e-
→ → → → → →
flank, the position relationship between σa and σd is i a = i d , j a = j d and k a = k d .
2.2. Geometrical parameters for generating tapered surface
Using the geometrical relationship in Fig. 3 and the spherical vector function [42], the equation for the generating tapered surface
is expressed in σa as
4
( )
→ → ( θ, δ )
r a = um (1)
a g
a
where the notations u and θ are two variables for the generating tapered surface. The symbol δg is the half taper angle for the generating
→ → →
tapered surface. The vector →m a (θ, δg ) = sinδg cosθ i a + sinδg sinθ j a + cosδg k a and is known as the spherical vector function [42].
Then, by Eq. (1), the normal vector n for the generating tapered surface is acquired in σ as
→
a
( ) ( )
∂
→
ra →
∂ ra
a
× a ( )
(→
n )a = ⃒ ( ∂θ ) ( ∂u ) ⃒ = →
n a θ, δg (2)
⃒∂ → → ⃒
⃒ ra ∂ r a ⃒
⃒ a⃒
⃒ ∂θ ×
a
∂u ⃒
⃒ ⃒
→
r a )a →
∂( r )
where the partial derivatives = usinδg →
g a (θ) and ∂ua a = → m a (θ,δg ). The vectors →
g a (θ) and → n a (θ, δg ) are called the circular vector
∂(
∂θ
→ →
function and the spherical vector function, respectively [42]. The vectors g a (θ) = − usinδg sinθ i a + usinδg cosθ j a and →
→ n a (θ, δg ) =
→ → →
cosδg cosθ i a + cosδg sinθ j a − sinδg k a . Besides, Eq. (2) illustrates that the direction of (→ n )a is oriented from the grinding wheel solid to
space.
According to the differential geometry [43], taking the direction of the straight edge line of the conical surface of the grinding
wheel as its first principal direction, the unit vector → g 1 of the first principal direction can be obtained from Eq. (1) in σa . Next, to ensure
that the established principal frame is right-handed orthogonal, its other principal direction → g 2 can be obtained in σ a using the cross
product of the unit normal vector (→ n )a in Eq. (2) and the first principal direction (→ g 1 )a . The results of these two principal directions
(→g 1 )a and (→
g 2 )a are calculated as
( )
( ) ∂ →ra ( )
( ) ( )
→
g1 = a
=→ m a θ, δg , → g 2 = (→ n )a × → g1 =− → g a (θ) (3)
a ∂u a a
Thus, employing Eqs. (2) and (3), it is possible to create a principal frame σM {M; →
g 1, →
g 2, →n } at any point M of the generating tapered
surface. Then, two principal curvatures k1 and k2 in each of the principal directions (→ g 1 )a and (→g 2 )a can be solved as
1
k1 = 0, k2 = − (4)
utanδg
2.3. Grinding engagement function and equation of worm helicoid
From the coordinate settings in Figs. 2 and 3(b), as the frame σ a is set differently on the grinding wheels for grinding different flanks
for the worm, the equations for the generating tapered surface obtained in σ d are different through the coordinate transformation
σa → σ d . Thus, for ease of calculation, the equations for the generating tapered surface can be expressed uniformly in σd as
( ) ( )
(π )→ (π )→ rg →
→ (S) S (S)
r d = usinδg sin − θ i d + ( − 1) usinδg cos − θ j d + ( − 1) ucosδg − S (S)
S
k d , (S = 1, 2) (5)
d S S tanδ g
where the symbol rg indicates the radius for the big end of the grinding wheel.
Likewise, using the coordinate transformation σa → σ d , the normal vectors → n for the generating tapered surfaces are represented
consistently in σ d as
(π )→ (π )→ →
(→
n )d = cosδ(S)
g sin − θ i d + ( − 1)S cosδ(S)
g cos − θ j d + ( − 1)S+1 sinδ(S)
g k d , (S = 1, 2) (6)
S S
g 1 and →
Furthermore, the principal directions → g 2 for the generating tapered surface are expressed uniformly in σ d as
( ) (π )→ (π )→ →
→
g 1 = sinδ(S)
g sin − θ i d + ( − 1)S sinδ(S)
g cos − θ j d + ( − 1)S cosδ(S)
g kd (7)
d S S
( ) (π )→ (π )→
→
g 2 = cos − θ i d + ( − 1)S+1 sin − θ j d (8)
d S S
Then, after the coordinate transformation σ d → σ o1 , the radius vectors → r d and the normal vectors →
n are represented in σ o1 as
( ) [ ] [ ]( )
→ → → → →
→rd = R j o1 , γ R i od , εS →r d = xo1 i o1 + yo1 j o1 + zo1 k o1 (9)
o1 d
5
[ ] [ ]
→ → → → →
n )o1 = R j o1 , γ R i od , εS (→
(→ n )d = nx i o1 + ny j o1 + nz k o1 (10)
→ →
where the symbols R[ j o1 , γ] and R[ i od , εS ] indicate the rotational transformation matrix [42]. After calculation, the components of
r d )o1 from Eq. (9) are obtained as
(→
rg cosεS sinγ rg sinεS rg cosεS cosγ
xo1 = Ax u + (− 1)S+1 , yo1 = Ay u + (− 1)S , zo1 = Az u + (− 1)S+1 (11)
tanδ(S)
g tanδ (S)
g tanδ(S)
g
nx sinδg +(− 1)S cosεS sinγ ny sinδg +(− 1)S+1 sinεS nz sinδg +(− 1)S cosεS cosγ
(S) (S) (S)
where Ax = (S) , Ay = (S) and Az = (S) . The three coefficients Ax , Ay and Az are the func
cosδg cosδg cosδg
tions of the variable θ.
After calculation, the three components of (→ n )o1 in Eq. (10) can be acquired as
(π ) [ (π ) ]
nx = cosδ(S)
g cosγsin − θ + (− 1)S cosδ(S)
g sinεS cos − θ − sinδ(S)
g cosεS sinγ (12)
S S
[ (π ) ]
ny = (− 1)S cosδ(S)
g cosεS cos − θ + sinδ(S)
g sinεS (13)
S
(π ) [ (π ) ]
nz = − cosδ(S)
g sinγsin − θ + (− 1)S cosδ(S)
g sinεS cos − θ − sinδ(S)
g cosεS cosγ (14)
S S
where the coefficients nx , ny and nz in Eqs. (12)-(14) are also the functions of the variable θ.
→
Generally speaking, the angular velocity for the worm rough turning about the axial line k 1 can be assumed as |→ ω | = 1rad /s.
Because the grinding wheel tends to be a rigid rotary body, its rotary motion cannot impact the grinding engagement when machining
the rough. The angular speed for the generating tapered surface can thus be omitted. Consequently, the relative angular velocity →
ω d1 of
the grinding engagement is acquired in σ o1 as
( )
→ →
ω d1 = 0 − (→ω )o1 = − k o1 (15)
o1
→
Next, based on the reference [42], the relative velocity V d1 of the arbitrary contact point is yielded by using Eqs. (9) and (15) as
( ) ( ) ( ) ( ̅̅̅→)
→ d ( ̅̅̅→) → → →
V d1 = →ω d1 × →
rd − (→
ω )o1 × O1 Od + O1 Od = (yo1 + ad ) i o1 − xo1 j o1 − p k o1 (16)
o1 o1 o1 o1 dφ o1
̅̅̅→ → →
where (O1 Od )o1 = ad j o1 − pφ k o1 .
→
Thereupon, through the normal vector (→ n )o1 and the relative velocity ( V d1 )o1 obtained in Eqs. (7) and (16), the engagement
function during grinding the worm with the generating tapered surface can be acquired as
( )
→
Φd (u, θ) = (→
n )o1 ⋅ V d1 = Ad u + Bd (17)
o1
( ) ( )
where the coefficients Ad = (− 1)S+1 sinεS cosγsin πS − θ − sinγcos πS − θ and Bd = − Ad rg cosδSg cotδSg + ad nx − pnz .
→
When grinding the worm rough, the generating tapered surface turns about the worm axial line k o1 and makes a translational
→
motion along k o1 . At this moment, the generating tapered surface will form the action surface for grinding the worm and, from Eq. (9),
its equation can be obtained in σo1 as
( ) ( ) ( ̅̅̅→) → → →
→r1 = → rd + O1 Od = xo1 i o1 + (yo1 + ad ) j o1 + (zo1 − pφ) k o1 , Φd (u, θ) = 0 (18)
o1 o1 o1
From Eq. (18), the equation of the helicoid for the tapered enveloping cylindrical worm is expressed in σ 1 as
( ) [ ]( )
→ → → →
r 1 = R k 1, − φ →
→ r1 = x1 i 1 + y1 j 1 + (zo1 − pφ) k 1 , Φd (u, θ) = 0 (19)
1 o1
where the coefficients x1 = xo1 cosφ + (yo1 +ad )sinφ and y1 = − xo1 sinφ + (yo1 + ad )cosφ. If S=1, Eq. (19) stands for the i-flank for the
worm helicoid, and if S=2, Eq. (19) indicates the e-flank.
From the meshing equation Φd (u, θ) = 0, only two of the three curvilinear coordinates u, θ and φ in Eq. (19) are independent.
Consequently, when the kinematic variable φ for the worm rough is specified, a contact line will be acquired between the worm
helicoid and the generating tapered surface. Based on this, during grinding, the generating tapered surface is kept to a linear contact
with the worm tooth surface at every instant.
6
2.4. Characteristic parameters for grinding engagement
Using the grinding engagement function Φd (u, θ) from Eq. (17), the grinding engagement limit function [19] can be worked out as
∂Φd
Φdφ = =0 (20)
∂φ
Because the grinding engagement limit function Φdφ in Eq. (20) is always zero, the grinding engagement limit line is the contact line
during processing. Under such circumstances, the contact region will degrade to the engagement limit line. It implies that only the
points on the engagement limit line satisfy the grinding engagement equation Φd (u, θ) = 0.
Using the rotation transformation σd → σo1 , the two principal direction vectors →
g 1 and →
g 2 of the generating surface in Eq. (7) and
Eq. (8) can be represented in σ o1 as
( ) [ ] [ ]( )
→ → → → →
→
g1 = R j o1 , γ R i od , εS →g 1 = Ax i o1 + Ay j o1 + Az k o1 (21)
o1 d
( ) [ ] [ ]( )
→ → → → →
→
g2 = R j o1 , γ R i od , εS →g 2 = g2x i o1 + g2y j o1 + g2z k o1 (22)
o1 d
( ) ( )
where the components g2x = cosγcos πS − θ + g2y tanεS sinγ, g2y = (− 1)S+1 cosεS sin πS − θ and g2z = cos
− 1
εS (g2x sinγ − g2y tanεS ).
Thereupon, according to the meshing theory [42], using the principal frame σ M {M; g 1 , g 2 , n 1 } and with the help of Eqs. (16),
→ → →
→
(19), (21), and (22), the normal vector N d for the contact line during grinding the worm helicoid is obtained as
( ) ( ) ( )
→
Nd = − g2z →g1 +μ → g2 (23)
o1 o1 o1
1 →
where the coefficient μ = − (S) ( V d1 )o1 g 2 )o1 + Az .
⋅ (→
utanδg
By Eqs. (16), (20), and (23), the curvature interference limit function [42] for grinding engagement is acquired as
( ) ( ) ( ) ( ) [ ( ) ( ) ]( ) ( )
→ → → 1 → →
Ψd = N d ⋅ V d1 + Φdφ = − g2z V d1 →
⋅ g1 + − V d1 ⋅ →
g 2 + A z V d1 ⋅ →
g2 (24)
o1 o1 o1 o1 utanδ(S)
g o1 o1 o1 o1
→ rg Ad →
where the dot products ( V d1 )o1 ⋅ (→
g 1 )o1 = − (S) + ad Ax − pAz and ( V d1 )o1 ⋅ (→
g 2 )o1 = g2x (yo1 + ad ) − g2y xo1 − pg2z .
cosδg
Employing the meshing theory [19,42], the curvature parameters for the worm helicoid, such as the normal curvatures kξ and kη
(1) (1)
Fig. 4. Coordinate system setting to study meshing for face worm gear drive.
7
following the two principal directions (→

g 1 )o1 and (→
g 2 )o1 , and the geodesic torsion τξ along the direction (→
g 1 )o1 , can be calculated
(1)
directly as
g22z (1) μ2 (1) μg2z

(25)
(1)
kξ = − , kη = k2 − ,τ =
Ψd Ψd ξ Ψd
3. Meshing of face worm gear with hardened cylindrical worm
3.1. Meshing function and tooth surface equation for face worm gear
Usually, to obtain the line contact face worm gear drive, the hob for machining the face worm gear should have exactly the same
generating surface as the matched worm helicoid. In this case, the machining procedure for the face worm gear completely replicates
the meshing procedure. In this section, thus, no differentiation is intended to be applied concerning the cutting engagement for the face
worm gear with the working meshing for the face worm gear drive.
To reach a better meshing property of the face worm gear drive, the direction of the worm thread should be opposite to the turning
direction of the matched worm gear tooth [19]. Since the worm mentioned above is right-handed, the direction of turning for the worm
gear should be left-handed. The turning direction of the worm gear is defined by looking on it from the center of the worm gear to its
addendum circle on the side with the worm, as shown in Fig. 4. Furthermore, for convenience, the flank for the worm close to the
central point of the worm gear can be specified to be the worm inner end. The other flank far from the central point for the worm gear
can be assigned to be the worm outer end, as shown in Fig. 4.
→
To depict the original and current locations for the worm gear, as illustrated in Fig. 4, a stationary orthogonal frame σ o2 {O2 ; i o2 ,
→ → → → → → →
j o2 , k o2 } and a rotating orthogonal frame σ 2 {O2 ; i 2 , j 2 , k 2 } are established. The unit vectors k o2 = k 2 and they follow the axis of
→ → → →
the worm gear. The orientation of k o2 is chosen according to the right-hand screw rule. k o2 is perpendicular to k o1 . The vector i o2 is
→ → → → →
the common perpendicular line for k o1 and k o2 , which parallels with i o1 . The minimum length between k o1 and k o2 is the straight-
̅̅→
line segment |O2 O| which can be referred to as the center distance a of the face worm gear drive.
→ → → → → →
To more clearly represent the relation between σ o1 {O1 ; i o1 , j o1 , k o1 } and σ o2 {O2 ; i o2 , j o2 , k o2 }, an intermediate orthogonal
→→→ → → → →
frame σ{O; i , j , k } is established, whose unit vectors k = k o1 and j = j o1 .
→
While the worm is rotated about the axial line k 1 , the helical surface develops a family {S1 } for single parametric surfaces.
(S)
Employing the coordinate conversion σ1 → σo1 , the equation of {S1 } is obtained from Eq. (19) as
(S)
( ∗) [ ]( )
→ ∗ → → →
→
r1 = R k o1 , φ1 →r 1 = xo1 i o1 + y∗o1 j o1 + (zo1 − pφ) k o1 , Φd (u, θ) = 0 (26)
o1 1
where x∗o1 = xo1 cos(φ1 − φ) − (yo1 +ad )sin(φ1 − φ) and y∗o1 = xo1 sin(φ1 − φ) + (yo1 + ad )cos(φ1 − φ).
Thereupon, using the coordinate conversion σ1 → σo1 , the normal vector → n of {S1 } is represented in σo1 by Eq. (10) as
∗ (S)
[ ]
→ → → →
(→n )o1 = R k o1 , φ1 − φ (→ (27)
∗
n )o1 = n∗x i o1 + n∗y j o1 + nz k o1 , Φd (u, θ) = 0
where the components n∗x = nx cos(φ1 − φ) − ny sin(φ1 − φ) and n∗y = nx sin(φ1 − φ) + ny cos(φ1 − φ).
Normally, the worm angular velocity can be assumed to be |→ ω 1 | = 1rad /s when meshing [30]. Thereupon, the angular velocity for
the face worm gear should be |→ω 2 | = 1 /i12 rad/s and the angular velocity →ω 2 should be pointed to the opposite orientation of the vector
→
k o2 because the worm gear is left-handed, as shown in Fig. 3(a). Thus, the relative angular velocity → ω 12 for the face worm gear pair is
acquired in σo1 as
( ) ( ) ( ) 1→ →
→ω 12 = →
ω1 − → ω2 =− j + k o1 (28)
o1 o1 o1 i12 o1
̅̅̅→
Using the geometrical relation in Fig. 4, the vector O2 O1 can be represented in σ o1 as
( ̅̅̅→) ( )
→ LW →
O2 O1 = a i o1 + zA + k o1 (29)
o1 2
in which the sign zA stands for the worm axial installation distance and zA = kA a where kA is a coefficient. The notation LW is the worm
thread length.
→
Employing the reference [42], the relative velocity V 12 for the face worm gear drive of an arbitrary contact point is represented in
σo1 as
( ) ( ) ( ∗) ( ) ( ̅̅̅→)
→ → → →
V 12 = → ω 12 × → r1 − → ω 2 × O2 O1 = Vx i o1 + Vy j o1 + Vz k o1 (30)
o1 o1 o1 o1 o1
8
(
) x∗ +a
where the components Vx = − y∗o1 − zo1 − pφ + zA + L2W , Vy = x∗o1 , and Vz = o1i12 .
1
i12
→
Thereupon, from the normal vector → n in Eq. (27) and the relative velocity V 12 in Eq. (30), the meshing function between the
∗
worm machined by the generating tapered surface and the face worm gear is acquired as
( )
→ 1
Φ(u, θ, φ, φ1 ) = (→ (31)
∗
n )o1 ⋅ V 12 = [Asin(φ1 − φ) + Bcos(φ1 − φ) + C]
o1 i12
( ) ( )
where the coefficients A = ny zo1 − pφ +zA +L2W − nz (yo1 +ad ), B = − nx zo1 − pφ +zA +L2W + nz xo1 and C = nz (a − i12 p).
Finally, form Eqs. (26) and (31), the tooth surface equation for the face worm gear is obtained as
⎧
⎪ ( ) [ ]{ [ ] ( ̅̅̅→) }
⎪
⎪
⎪ → → → π (→∗ ) → → →
⎪
⎪ r 2 = R k 2 , φ2 R i o2 , − r1 + O2 O1 = x2 i 2 + y2 j 2 − y∗o1 k 2
⎨ 2 2 o1 o2
(32)
⎪
⎪ Φd (u, θ) = 0
⎪
⎪
⎪
⎪
⎩ Φ(u, θ, φ, φ1 ) = 0
where the components x2 = xo2 cosφ2 − yo2 sinφ2 and y2 = xo2 sinφ2 + yo2 cosφ2 . The coefficients xo2 = x∗o1 + a and yo2 = zo1 − pφ + zA
+ L2W . Besides, if S=1, Eq. (32) means the convex flank for the face worm gear. If S=2, Eq. (32) stands for the concave flank.
From Φd (u, θ) = 0 in Eq. (19) and Φ(u, θ, φ, φ1 ) = 0 in Eq. (32), only two of the four variables u,θ, φ and φ1 are independent of each
other, so both tooth surface equations in Eqs. (19) and (32) are in the two-parameter form. Thus, when a value of the kinematic
parameter φ1 is determined, a corresponding instantaneous contact line and its conjugate line will be acquired on the worm helicoid
and face worm gear tooth surface. This shows that the face worm gear drive with the hardened cylindrical worm proposed in this paper
can maintain line contact at each moment.
3.2. Meshing characteristics of face worm gear drive
By finding the partial derivative for the meshing function Φ in Eq. (31) about the variable φ1 , the meshing limit line function for the
face worm gear drive is yielded as
1
Φφ1 = [Acos(φ1 − φ) − Bsin(φ1 − φ)] (33)
i12
in which the meshing limit line should be the envelope for the instantaneous contact lines [21].
At any meshing point, an orthogonal moving frame σP {P; → α ξ, → n } can be established on the worm helicoid. The unit base
α η, →
∗
vectors →
α and →α in σ locate at the common tangential plane for the two contacting tooth surfaces and they can be obtained from
ξ η o1
Eqs. (21) and (22) using the rotation matrix method as
( ) [ ]( )
→ → → → →
αξ = R k o1 , φ1 − φ → g1 = αξx i o1 + αξy j o1 + Az k o1 (34)
o1 o1
( ) [ ]( )
→ →
α = R k o1 , φ1 − φ →g2
(35)
η
o1 o1
→ → →
= αηx i o1 + αηy j o1 + g2z k o1
where the components αξx = Ax cos(φ1 − φ) − Ay sin(φ1 − φ), αξy = Ax sin(φ1 − φ) + Ay cos(φ1 − φ), αηx = g2x cos(φ1 − φ) − g2y sin(φ1 −
φ), and αηy = g2x sin(φ1 − φ) + g2y cos(φ1 − φ). It is worth noting that the unit base vectors →
α ξ and →
α η are the arbitrary orthogonal
directions on the worm helicoid.
→
Thereupon, by means of Eqs. (34) and (35), the normal vector N for the contact line [21,42] is obtained in this moving frame σ P as
(→) ( ) ( )
N = Nξ → αξ + Nη → αη (36)
o1 o1 o1
(1) → → (1) → (1) →

where the coefficients Nξ = kξ ( V 12 )o1 ⋅ (→ → → → →
ξ ( V 12 )o1 ⋅ ( α η )o1 + ( ω 12 )o1 ⋅ ( α η )o1 and Nη = τξ ( V 12 )o1 ⋅ ( α ξ )o1 + kη ( V 12 )o1 ⋅
α ξ )o1 + τ(1)
→
η o1
→ →
( α ) − (ω ) ⋅ ( α ) . 12 o1 ξ o1
With the help of Eqs. (31), (34), and (35), the dot products contained in the components Nξ and Nη in Eq. (36) can be worked out as
( ) ( )
→ ( ) ( ) x∗ + a
V 12 ⋅ →
αξ = Ax x∗o1 − Ay Vx sin(φ1 − φ) + Ay x∗o1 + Ax Vx cos(φ1 − φ) + o1 Az (37)
o1 o1 i12
9
( ) ( )
→ ( ) ( ) x∗ + a
V 12 ⋅ →
αη = g2x x∗o1 − g2y Vx sin(φ1 − φ) + g2y x∗o1 + g2x Vx cos(φ1 − φ) + o1 g2z (38)
o1 o1 i12
( ) ( ) 1
→ω 12 ⋅ →αη =− αξy + Az (39)
o1 o1 i12
( ) ( ) 1
→ω 12 ⋅ →αξ =− αηy + g2z (40)
o1 o1 i12
Thereupon, using Eqs. (24) and (37-40), the components Nξ and Nη can be yielded as
{ }
g2z [ ( ∗
) ( )] g2x
Nξ = − g2z Ax xo1 − Ay Vx + μ g2x x∗o1 − g2y Vx − sin(φ1 − φ)
Ψd i12
{ } [ ( ∗ ) ] (41)
g2z [ ( ) ( )] g2y g2z xo1 + a (μ − Az ) + i12 Ψd
+ − g2z Ay x∗o1 + Ax Vx + μ g2y xo1
∗
+ g2x Vx − cos(φ1 − φ) + g2z
Ψd i12 i12 Ψd
{ }
μ [( ) ( )] ( ) Ax
Nη = g2z Ax x∗o1 − Ay Vx − μ g2x x∗o1 − g2y Vx + k2 g2x x∗o1 − g2y Vx + sin(φ1 − φ)
Ψd i12
{ }
μ [ ( ) ( )] ( ) Ay
+ g2z g2x x∗o1 − g2y Vx − μ g2y x∗o1 + g2x Vx + k2 g2y x∗o1 + g2x Vx + cos(φ1 − φ) (42)
Ψd i12
( ∗ ) [ ]
x + a g2z μ
+ o1 (Az − μ) + k2 − Az
i12 Ψd
Thereupon, the curvature interference limit function [21] of the face worm gear drive is acquired by Eqs. (33), (36-38), (41) and (42)
as
(→) (→ ) (
→
) ( ) (
→
) ( )
Ψ(u, θ, φ, φ1 ) = N ⋅ V 12 + Φφ1 = Nξ V 12 ⋅ → αξ + Nη V 12 ⋅ → α η + Φφ1 (43)
o1 o1 o1 o1 o1 o1
Besides, employing the computation method for the induced principal curvature from Refs. [21,42], it is possible to obtain the induced
principal curvature for the meshing point to the face worm gear drive from Eqs. (41-43) as
Nξ2 + Nη2
kN(12) = (44)
Ψ
Based on the Hertz formula [44], the contact stress for the face worm gear drive is positively correlated with the absolute value for the
induced principal curvature. Thus, from the magnitude of its absolute value, it is possible to qualitatively evaluate the characteristics of
the contact stress within the entire meshing zone. Furthermore, from Ref. [42], the induced principal curvature is also utilized to
determine whether the curvature interference for the face worm gear drive occurs.
→
The acute angle between the relative velocity ( V 12 )o1 and the tangential vector for the contact line can be referred to as the sliding
angle [21,42]. From Eqs. (30), (33), (41-43), the sliding angle for any contact point is solved as
⎛ ⎞
⎜ |Ψ − Φφ1 | ⎟
Ω = arcsin⎜ ⎟
⎝⃒⃒(→ ) ⃒⃒√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅⎠ (45)
⃒ V 12 ⃒ N2 + N2
⃒ ⃒ ξ η
o1
Based on Ref. [21], the nearer the sliding angle Ω reaches 90◦ , the more excellent the lubrication performance.
Fig. 5. Projection of worm helicoid in axial section.
10
4. Determination of dimension for face worm gear drive based on reference point
4.1. Reference point at worm helicoid and boundary equation of worm
To facilitate the rough determination of the face worm gear drive and guarantee its conjugation, the reference point P is designated
at the addendum on the worm inner end, as illustrated in Fig. 5.
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
As shown in Fig. 5, the coordinate system O1 − zo1 , x∗o1 2 + y∗o1 2 is established within the axial section of the worm, and its origin is
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
O1. In O1 − zo1 , x∗o1 2 + y∗o1 2 , the coordinates of the reference point P are ( − LW /2,ra1 ). Thereupon, using the components xo1 , yo1 , and
zo1 in σ o1 in Eq. (11) and combining the meshing equation Φd = 0 of the grinding engagement, and the meshing equation Φ = 0, the
nonlinear equations for determining the curvilinear coordinates for the reference point P are obtained as
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
Φd (u, θ) = 0, Φ(u, θ, φ, φ1 ) = 0, zo1 − pφ = − LW / 2, x2o1 + (yo1 + ad )2 = ra1 (46)
where the symbol ra1 represents the worm addendum circle radius.
Thus, using the first and third equations in Eq. (46), it can be solved as
[ ]
Bd 1 (− 1)S+1 rg cosεS cosγ LW
u(θ) = − , φP (θ) = Az u(θ) + + (47)
Ad p tanδ(S)
g
2
Next, a nonlinear equation about the variable θ is acquired from the second equation of Eq. (46) as
[ ]2 [ ]2
fP (θ) = Ax u(θ)tanδ(S) S
g − (− 1) rg cosεS sinγ + Ay u(θ)tanδ(S) S (S)
g + (− 1) rg sinεS + ad tanδg
2
− ra1 tan2 δ(S)
g = 0 (48)
To solve the equation of fP (θ) = 0 in Eq. (48), the geometric construction method [31] can be first employed to obtain its iterative
initial value. Then, the value of θ can be solved using the iteration method and denoted as θP. By taking the value of θP into Eq. (47), the
values of u and φ for the reference point P will be acquired, which are denoted as uP and φP.
Besides, from Eq. (48), the function fP (θ) is only relevant to the radial location for the reference point P. This, therefore, shows that
the values of u and θ are the same for the points having the identical radius on the worm helicoid. However, the variable φ needs to be
further calculated based on the axial location for the reference point P.
Finally, by taking the values of uP, θP and φP into the worm helicoid equation from Eq. (19), the radius vector for the reference point
P in σ o1 is worked out as
( ) → → →
→rP = XP i o1 + YP j o1 + ZP k o1 (49)
o1
Thus, from Fig. 5, using Eq. (49), the boundary equations for the worm helicoid are obtained as follows.
The equations for the worm addendum and dedendum:
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ √̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ √̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ √̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
x∗o1 2 + y∗o1 2 − X 2P + Y 2P = 0, x∗o1 2 + y∗o1 2 − X 2P + Y 2P + hw = 0 (50)
The equations of the worm inner end and outer end:

zo1 − pφ − ZP = 0, zo1 − pφ − ZP − LW = 0 (51)
in which the notation hw stands for working tooth height of the worm.
4.2. Limit axial installation distance of worm
Research shows that the reference point P situated at the intersection between the worm addendum and the worm inner end is
closest to the meshing limit line. That illustrates when the designed parameters cannot be reasonably matched, the meshing limit line
first comes into the worm helicoid from this reference point P, which in turn affects the worm conjugation. Thus, it is proposed here
that the distance between the reference point P and the intersection of the meshing limit line with the worm addendum is used to
estimate whether the meshing limit line comes into the worm working region. Then, considering the limiting case, when the reference
point P falls at the meshing limit line, the curvilinear coordinates for the reference point P should then satisfy both the meshing
equation Φ(u, θ, φ, φ1 ) = 0 in Eq. (31) and the meshing limit line equation Φφ1 (u, θ, φ, φ1 ) = 0 in Eq. (33). Thereupon, by combining
Eqs. (31) and (33), it can be obtained as
⃒ ⃒ ⃒ ⃒
⃒− C B ⃒ ⃒A − C⃒
⃒ ⃒ ⃒ ⃒
⃒ 0 − A⃒ − AC ⃒ B 0 ⃒ − BC
sin(φ1 − φ) = ⃒⃒ ⃒ =
⃒ , cos(φ1 − φ) = ⃒ ⃒
⃒ A B ⃒ = A2 + B2 (52)
⃒A B ⃒ A2 + B2 ⃒ ⃒
⃒B − A⃒ ⃒B − A⃒
11
Thereupon, by bringing Eq. (31) into Eq. (52) and using the trigonometric constant sin2 (φ1 − φ) + cos2 (φ1 − φ) = 1, it can be derived
as
[ ( ) ]2 [ ( ) ]2
LW LW
A2 + B2 − C2 = ny zo1 + zA + − pφ − nz (yo1 + ad ) + nx zo1 + zA + − pφ − nz xo1 − n2z (a − i12 p)2
2 2
( )( )2 ( )
= n2x + n2y zo1 + zA +
LW [ ]
− pφ − 2nz nx xo1 + ny (yo1 + ad ) zo1 + zA +
LW [
− pφ + n2z x∗o1 2 + y∗o1 2 − (a − i12 p)2
] (53)
2 2
( ) [ ] [ ]
= n2x + n2y I 2 (zA ) − 2nz nx xo1 + ny (yo1 + ad ) I(zA ) + n2z x∗o1 2 + y∗o1 2 − (a − i12 p)2 = 0
where the variable I(zA ) = zA + zo1 − pφ + L2W .

[ny xo1 − nx (yo1 +ad )]2
From Eq. (53), it is a quadratic equation concerning I(zA ). Therefore, when satisfied (a − i12 p)2 ≥ n2x +n2y
, it means that Eq.
(53) has solutions. Thus, once the curvilinear coordinates uP, θP, and φP of the reference point P are determined using Eqs. (47) and
(48), the axial installation distance zL while the reference point P locates at the meshing limit line is worked out by Eq. (53) as
(S)
{ √̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
( ) }
1 [ ]2 [ ]
z(S)
L = 2 (− 1)S+1
nz n 2 + n2 (a − i p)2 −
x y 12 n y x o1 − n x (y o1 + a d ) + nz nx xo1 + ny (yo1 + a d ) , , (S = 1, 2) (54)
nx + n2y
As can be seen from Eq. (54), when the designed axial installation distance zA is equal to this axial installation distance z(S)
L , the
reference point P situates at the meshing limit line. Therefore, the axial installation distance z(S)
L is called the limiting installation
distance. The axial installation distance should be designed to ensure that the designed axial installation distance zA > z(S)
L which can
ensure that the meshing limit line lies outside the worm helical surface and guarantee the worm conjugation.
Eq. (54) also illustrates that this limiting installation distance zL is only related to the process parameters, the center distance a, the
(S)
transmission ratio i12, and the helical parameter p, but not to the thread length LW of the worm.
4.3. Boundary equations of face worm gear tooth surface
For establishing the boundary equations for the face worm gear, the reference point P is placed in the frame σo2 . Thereupon, the
C ̅
meshing equation in Eq. (31) is first replaced with a trigonometric function sin(φ1 − φ + φ0 ) = − √̅̅̅̅̅̅̅̅̅̅
A2 +B2
. The axial installation
distance zA in coefficients A and B can be selected based on the limit axial installation distance zL in Eq. (54). Thereupon, in one
(S)
meshing period of the worm pair, from sin(φ1 − φ + φ0 ), one of the solutions of the worm angle φ1 can be expressed in terms of θ and φ.
C
φ1 (θ, φ) = φ − φ0 − arcsin √̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ (55)
A2 + B 2
B ̅ A ̅
in which the trigonometric functions for the angle φ0 are sinφ0 = √̅̅̅̅̅̅̅̅̅̅
A2 +B2
and cosφ0 = √̅̅̅̅̅̅̅̅̅̅
A2 +B2
.
After bringing the curvilinear coordinates uP, θP, and φP for the reference point P into Eq. (55), the value of φ1 for the reference
point P is acquired, which is denoted as φP1 .
By the coordinate transformation σo1 → σ → σ o2 , the radius vector →r P in σo2 is obtained from Eq. (49) as
Fig. 6. Projection of boundaries for worm gear tooth surface in axial section.
12
( ) [ ] ( )
→ π (→ ) ( ̅̅̅→) → LW → →
→
rP = R i o2 , − rP + O2 O1 = (XP + a) i o2 + ZP + zA + j o2 − Yp k o2 (56)
o2 2 o1 o2 2
Since the indexing surfaces for the face worm gear pair are cylindrical and planar, the rough dimension for the face worm gear can
be estimated from the geometrical relationship according to Fig. 4. The origin O 2 is the intersection of the indexing plane with the axis
′
of the face worm gear. Thus, from Fig. 4, the outside radius ra2 for the face worm gear can be estimated using the center distance a, the
axial installation distance zA, and the worm thread length LW. The value of the inner radius rf2 for the face worm gear can be estimated
from the radius vector → r P in Eq. (49). Their equations are
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ √̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
ra2 = (zA + LW )2 + a2 , rf2 = X 2P + Y 2P (57)
Thus, using the geometrical relation from Fig. 6, the coefficient kg for the face width b2 for the face worm gear is obtained as
ra2 − rf2
kg = (58)
a
Finally, from Fig. 6, it is possible to determine the coordinates of three points AP , BP and CP in Fig. 6. In O2 − ρ2 ,y∗o1 , the coordinates of
(√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ ) (√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
( )2 ( )2
AP , BP and CP are (XP + a)2 + ZP + zA + L2W , YP − hw2 , (XP + a)2 + ZP + zA + L2W , YP +
) (√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ )
( )2
c and (XP + a)2 + ZP + zA + L2W + b2 ,YP + c , respectively. The symbol hw2 is the working tooth height for the face worm gear.
The symbol c is its tip clearance.
Thereupon, the boundary equations for the face worm gear tooth surface can then be represented as
The equations of addendum and dedendum for the face worm gear:
y∗o1 = YP + c, y∗o1 = YP − hw2 (59)
The equations for the inner and outer ends for the face worm gear:
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
( )2̅ √̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
( )2̅
LW LW
ρ2 − 2
(XP + a) + ZP + zA + = 0, ρ2 − 2
(XP + a) + ZP + zA + − kg ⋅ a = 0 (60)
2 2
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
in which the notation a stands for the center distance and the abscissa ρ2 = x22 + y22 .
5. Evaluation parameters of asymmetry for two flanks of tooth surfaces
5.1. Worm axial tooth profile and tooth profile angles
→ → →
To obtain the worm axial tooth profile, the frame σt {Ot ; i t , j t , k t } is first established on the worm axial section as illustrated in
→ → → →
Fig. 7, where the base vectors i t and k t lie within the axial section, and k t = k 1 .
→ →
From Fig. 7, the angle between the vectors i t and i 1 is μ, μ > 0. Since the worm tooth profile line is located at the worm axial
section, it can derive tanμ = − xytt from Fig. 7. Thus, using the equation for the worm helicoid from Eq. (19) and the coordinate trans
formation σ1 → σt , the equation for the worm axial tooth profile is obtained as
( ) → → → yt
→
r 1 (θ, φ) = xt i t + yt j t + (zo1 − pφ) k t , Φd (u, θ) = 0, tanμ = − (61)
t xt
Fig. 7. (a) Relation between coordinates σ 1 and σ t . (b) Worm axial tooth profile and tooth profile angle.
13
where xt = x1 cosμ − y1 sinμ and yt = x1 sinμ + y1 cosμ.

→
To study the worm axial tooth profile, a worm axial section is specified the axis i t can intersect with the worm pitch circle. The
intersection point on worm i-flank can be noted as point P1 and the intersection point on worm e-flank can be denoted as P2.
Since the points P1 and P2 are located on the worm pitch circle, the curvilinear coordinate θ of the points P1 and P2 can be solved
iteratively by replacing the radius ra1 of the worm outer circle in Eq. (48) with the radius r1. Besides, from Fig. 7, point P1 lies on the
→
unit vector i t . The axial length from the points P1 and P2 is the tooth thickness s1. Based on this, the curvilinear coordinate φ of the
points P1 and P2 can be solved from Eq. (48).
Thereupon, once the angles μ at the points P1 and P2 are determined, a function φ(θ) for the points on the worm profile lines which
y1
are denoted as φt (θ)(S = 1, 2) can be worked out using tanμ = − as
(S)
x1
xo1 tanμ + (yo1 + ad ) (2) xo1 tanμ + (yo1 + ad )

φ(1)
t (θ) = − 2π + arctan , φ (θ) = π + arctan (62)
xo1 − (yo1 + ad )tanμ t xo1 − (yo1 + ad )tanμ
Substituting u(θ) in Eq. (47) and φ(S)

t (θ)(S = 1, 2) in Eq. (62) into the first equation in Eq. (61), it can be obtained the vector equation
for the worm axial tooth profile within a single parameter θ as
( ) → →
→r 1 (θ) = xt i t + zt k t (63)
t
where xt = [xo1 cosμ +(yo1 +ad )sinμ]cosφ(θ) + [xo1 sinμ +(yo1 +ad )cosμ]sinφ(θ) and zt = zo1 − pφ(θ)
To calculate the worm axial tooth profile angle, initially, the first order derivative of Eq. (63) is employed to find the tangential
vector of the worm axial tooth profile as
( ’ ) → →
→r 1 (θ) = x’t i t + z’t k t (64)
t
where the coefficients of the tangential vectors xt = {xo1 cosμ + yo1 sinμ + [xo1 sinμ + (yo1 + ad )cosμ]φ }cosφ + {xo1 sinμ + yo1 cosμ
′ ′ ′ ′ ′ ′
− [xo1 cosμ + (yo1 + ad )sinμ]φ }sinφand zt = zo1 − pφ .

′ ′ ′ ′
From Eq. (18), the first derivative of the components xo1 , yo1 and zo1 is obtained as
[ ] [ ]
′ 1 ′ Ax ( ′ ′ ) ′ 1 ′ Ay ( ′ ′ )
xo1 = − Bd nx tanδ(S)
g + Bd Ad − Ad Bd , yo1 = − Bd ny tanδ(S)
g + Bd Ad − Ad Bd
Ad Ad Ad Ad
[ ]
1 Az ( ′ )
(65)
′ ′ ′
zo1 = − Bd nz tanδ(S)
g + Bd Ad − Ad Bd
Ad Ad
(π ) (π )
nx (θ) = − cosδ(S) − θ + (− 1)S sinγcosδ(S)
′
g cosγcos g sinεS sin − θ
S S
where (π ) (π ) (π ).
ny = (− 1) cosδg cosεS sin − θ and nz = cosδg sinγcos − θ + (− 1)S cosγcosδ(S)
S
′ ′
(S) (S)
g sinεS sin − θ
S ( ) ( ) S S
Moreover, Ad = − (− 1)S+1 sinεS cosγcos πS − θ − sinγsin πS − θ and Bd = − Ad rg cosδ(S)
g cotδg + ad nx − pnz .
′ ′ ′ (S) ′ ′
Next, taking the derivative of φt (θ)(S = 1, 2) in Eq. (62) can yield

(S)
( ′ ′ ) ( ′ ′ )
x tanμ + yo1 [xo1 − (yo1 + ad )tanμ] − xo1 − yo1 tanμ [xo1 tanμ + (yo1 + ad )]
(66)
′
φ (θ) = o1 [ 2 2]
xo1 + (yo1 + ad ) sec2 μ
In general, the tooth profile angle is the acute angle formed between the tangent of the worm axial tooth profile and the cross
′
section of the worm. Thus, by the equation of the tangent vector →
r 1 (θ) in Eq. (64), the tooth profile angle at any point on the worm
axial tooth profile can be obtained as
′
π xt
vS = − arctan ′ , (S = 1, 2) (67)
2 zo1 − pφ′
When the profile tooth angles vS for the two worm tooth profiles are different, it means that both flanks of the worm are asymmetrical.
It is therefore proposed that the asymmetry can be determined byIv = ||v1 | − |v2 ||. The larger the value of Iv, the more significant the
asymmetry on both flanks of the worm.
14
5.2. Geometry for line of section on worm gear tooth surface
In contrast to face gear drive [7], the tooth surface for face worm gear is not a plane but a surface. This leads to the line of section on
the worm gear tooth surface is not a straight line but a curve, as shown in Fig. 8(a). To study the geometrical characteristics of this line
of section, its equation should first be established. Thereupon, by associating the tooth surface equation for the worm gear in Eq. (32)
and the abscissa HA for the indexing plane in Fig. 6, the equation system for the line of section can be obtained as
( ) → → →
→
r 2 = x2 i 2 + y2 j 2 − y∗o1 k 2 , Φd (u, θ) = 0, Φ(u, θ, φ, φ1 ), y∗o1 = HA (68)
2
where the symbol HA is the coordinates of the indexing plane in the coordinate O2 − y∗o1 , ρ2 . Besides, it is clear from the fourth equation
y∗o1 = HA in Eq. (68) that this line of section is a plane curve.
Then, combining the third and fourth equations in Eq. (68) can obtain
{
xo1 sin(φ1 − φ) + (yo1 + ad )cos(φ1 − φ) = HA
(69)
Asin(φ1 − φ) + Bcos(φ1 − φ) = − C
From Eq. (68), the expressions for the trigonometric functions sin(φ1 − φ) and cos(φ1 − φ) can be solved as
⃒ ⃒ ⃒ ⃒
⃒ HA yo1 + ad ⃒ ⃒ xo1 HA ⃒
⃒ ⃒ ⃒ ⃒
⃒− C B ⃒ HA B + (yo1 + ad )C ⃒ A − C⃒ − xo1 C − HA A
sin(φ1 − φ) = ⃒⃒ ⃒ =
⃒ , cos(φ 1 − φ) = ⃒ ⃒
⃒ xo1 yo1 + ad ⃒ = xo1 B − (yo1 + ad )A (70)
⃒ xo1 yo1 + ad ⃒ xo1 B − (yo1 + ad )A ⃒ ⃒
⃒ A B ⃒ ⃒ A B ⃒
Thus, using the trigonometric constant equation can yield
[HA B + (yo1 + ad )C]2 + (xo1 C + HA A)2 − (xo1 B − HA A)2

{( ) 2 [ 2 ] }
= φ2 HA2 − xo1
2
BB + HA − (yo1 + ad )2 A2A + 2AA BB xo1 (yo1 + ad )
= p2 A1 φ2 + 2B1 pφ + C1 = 0
{ ( ) [ ] } (71)
+φ 2BB CB HA2 − x2o1 + 2AA CA HA2 − (yo1 + ad )2 + 2(AA CB + BB CA )xo1 (yo1 + ad ) + 2CHC [BB (yo1 + ad ) + AA xo1 ]
( ) [ ] [ ] 2
+CB2 HA2 − x2o1 + CA2 HA2 − (yo1 + ad )2 + 2CA CB xo1 (yo1 + ad ) + 2CHA [CB (yo1 + ad ) + CA xo1 ] + (yo1 + ad )2 + xo1
2
C
where the coefficients in Eq. (71) can be obtained as

( ) [ ]
A1 = HA2 − x2o1 n2x + HA2 − (yo1 + ad )2 n2y − 2nx ny xo1 (yo1 + ad )
{ [( )2 ] [( )2 ] ( )
B1 = nx CB Yp + hw2 − x2o1 − ny CA Yp + hw2 − (yo1 + ad )2 − xo1 (yo1 + ad ) ny CB − nx CA
( )[ ]}
+C Yp + hw2 nx (yo1 + ad ) − ny xo1
( )
( ) [ ] [ ] LW
C1 = CB2 HC2 − x2o1 + CA2 HC2 − (yo1 + ad )2 + 2CA CB xo1 (yo1 + ad ) + 2CHA ny xo1 − nx (yo1 + ad ) zo1 + zA +
2
[ 2 2
] 2
+ (yo1 + ad ) + xo1 C
Fig. 8. (a) Relation between coordinates σ 1 and σ t . (b) Worm axial tooth profile and tooth profile angle.
15
Thus, from Eq. (61), the function φ(θ) can be worked out and denoted by φL (θ) as
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
− B1 + (− 1)S B21 − A1 C1
(S)
φL (θ) = , (S = 1, 2) (72)
pA1
Finally, by substituting the functions u(θ) in Eq. (47), φL (θ)(S = 1, 2) in Eq. (72), and φ1 (θ, φ) in Eq. (55) into Eq. (32), the equation for
(S)
the line of section can be acquired as

( (S) ) → → →
→r L (θ) = xo2 (θ) i o2 + yo2 (θ) j o2 − HA k o2 , (S = 1, 2) (73)
o2
hw2
which is worth noting that the line of section is a plane curve and when the abscissa HA = Yp + 2 , it lies on the indexing plane.
5.3. Helix angle of midpoint on line of section
To determine whether these two lines of section on different flanks of the face worm gear are symmetrical, this paper proposes to
(S) ’
use the angle of the tangent vector → to the radius vector → of any point on the line of section, which is noted as the helix angle
(S)
r L r L
(S) ’
βwg , as shown in Fig. 8(b). Thus, by taking the derivative with Eq. (73), the tangent vector →
rL at any point on this line of section can
be obtained as
( (S) ’ ) → →
→r L (θ) = x’o2 (θ) i o2 + y’o2 (θ) j o2 , (S = 1, 2) (74)
o2
where xo2 (θ) = xo1 cos(φ1 − φ) + xo1 cos (φ1 − φ) − yo1 sin(φ1 − φ) − (yo1 +ad )sin (φ1 − φ) and yo2 (θ) = zo1 − pφ .
′ ′ ′ ′ ′ ′ ′ ′
After calculation, it can be derived from Eq. (70) as

′ ′ ′
[ ′ ′ ′ ′ ]
y C + (yo1 + ad )C + HA B [C(yo1 + ad ) + HA B] Bxo1 + xo1 B − yo1 A − A (yo1 + ad )
(75)
′
sin (φ1 − φ) = o1 − 2
Bxo1 − A(yo1 + ad ) [Bxo1 − A(yo1 + ad )]
′ ′ ′
[ ′ ′ ′ ′]
Cxo1 + xo1 C + HA A (xo1 C + HA A) Bxo1 + xo1 B − yo1 A − (yo1 + ad )A
(76)
′
cos (φ1 − φ) = − +
Bxo1 − A(yo1 + ad ) [Bxo1 − A(yo1 + ad )]2
′ ( ) ′ ( )
where A = ny zo1 − pφ + zA + L2W + ny (zo1 − pφ ) − nz (yo1 + ad ) − nz yo1 , B = − nx zo1 − pφ + zA + L2W − nx (zo1 − pφ ) + nz xo1 +
′ ′ ′ ′ ′ ′ ′ ′ ′
nz xo1 and C = nz (a − i12 p).

′ ′ ′
Finding the derivative of φ(θ) in Eq. (72) yields

⎧⎡ ⎤ ⎫
⎪
⎨ ′ ′ ′ [ √̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ ] ⎪ ⎬
1 ⎢ 2B1 B1 − A1 C1 − A1 C1 ⎥
(77)
′ ′ ′
φ (θ) = 2 ⎣ − B1 ± √̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ ⎦A1 − − B1 ± B21 − A1 C1 A1
pA1 ⎪
⎩ 2
2 B1 − A1 C 1
⎪
⎭
where A1 = − 2(nx xo1 + ny yo1 )[xo1 nx + ny (yo1 + ad )] + 2nx [nx (HA2 − x2o1 ) − ny xo1 (yo1 + ad )] + 2ny {ny [H2A − (yo1 + ad )2 ] − nx xo1 (yo1 +
′ ′ ′ ′ ′
ad )}
′ { } ′ ′ [ ]
B1 = − [2xo1 CB − (yo1 + ad )CA ]nx + [(yo1 + ad )CB + CHA ]ny xo1 + C HA nx (yo1 + ad ) − ny xo1
′ { [ ] } ′ ( ) ′ [ ]
− ny CA HA2 − (yo1 + ad )2 + [CB (yo1 + ad ) + CHA ]xo1 + nx CB HA2 − x2o1 − ny CA HA2 − (yo1 + ad )2
[ ′ ′ ( ′ ′ )] ′
− 2 yo1 CA2 − CA CB xo1 − CA CB xo1 + CA CB xo1 (yo1 + ad ) + 2CA CB xo1 yo1
′ { [ ′( ) ′ ] ′ [ ]}
and C1 = 2 CB CB HA2 − x2o1 − CB xo1 xo1 + CA CA HA2 − (yo1 + ad )2
{ ′[ ] [ ′ ′ ′ ′
]}( LW
)
+2HC C ny xo1 − nx (yo1 + ad ) + C ny xo1 + ny xo1 − nx (yo1 + ad ) − nx yo1 zo1 + zA +
2
{ ′ [ ] ′[ 2 2
] [ ′ ′ ]}
+C 2zo1 HA ny xo1 − nx (yo1 + ad ) + 2C (yo1 + ad ) + xo1 + C 2yo1 (yo1 + ad ) + 2xo1 xo1
S’
Thereupon, with the help of the equation for the radius vector →
r L in Eq. (73) and the tangent vector →
r L in Eq. (74), the helix angle
(S)
βwg at any point on the line of section can be solved as

′ ′
xo2 xo2 + yo2 yo2
β(S)
wg = arccos √̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅, (S = 1, 2) (78)
xo2 + yo2 ′ 2 x2o2 + y2o2 + H 2A
′2
⃒ ⃒
⃒ (2) ⃒
Similarly, we can evaluate the asymmetry on both flanks for one tooth on the worm gear by Iβwg = ⃒|β(1)
wg | − |βwg |⃒ which is the
16
difference between the absolute values of the helix angles β(S)

wg of both flanks of one tooth for the face worm gear.
6. Numerical example and discussion
6.1. Main parameters of face worm gear drive
For obtaining the main parameters of the face worm gear pair, the transmission ratio i12 and the center distance a of the worm pair
are first decided according to the requirements. According to the transmission ratio i12, the worm threads Z1 are selected. The radius for
the worm pitch circle is reasonably selected as a standard value from the gear handbook [21] based on the estimated result obtained
from the AGMA empirical formula. The modulus m is reckoned from the formula in Table 1 and selected as the standard value [21].
Then, using the coordinates and the curvilinear coordinates for the reference point P, the limiting axial installation distance of the
worm can be obtained from Eq. (57). To prevent the meshing limit line from being entered the worm helicoid and to ensure the
conjugation, the axial installation distance should be greater than the worm limit axial installation distance zL. The worm axial
installation distance is therefore chosen to be 0.6a. Thereupon, the boundaries for the face worm gear are obtained according to
Section 4.3. The formulae for the main design parameters and their computing outcomes are included in Table 1.
Besides, the necessary processing parameters are shown in Table 2.
6.2. Calculation for reference point P
To acquire the curvilinear coordinates of the reference point P, the image of fP (θ) in Eq. (48) is firstly drawn in Fig. 9. From Fig. 9,
the intersection point (177.61º, 0) between fP (θ) and the horizontal axis for the i-flank and the intersection point (269.4º, 0) for the e-
flank are taken as initial values for iteratively solving fP (θ). The numerical results for the curvilinear coordinates uP, φP, and φP1 of the
reference point P are acquired by bringing the value of θP into u(θ) and φ(θ) in Eq. (47), and φ1(θ, φ) in Eq. (55), respectively, and these
outcomes are included in Table 1. In addition, the numerical outcomes for the coordinates of the reference point P in σ are listed in
Table 1.
6.3. Computation of evaluation parameters of asymmetry
6.3.1. Boundaries of worm tooth profile and line of section for face worm gear tooth surface
From Fig. 10, the boundary points B1 and B2 of the worm tooth profile are the intersections between the worm tooth profile line
and the worm addendum and dedendum.
As the computing method for the curvilinear coordinate θ of the worm dedendum is basically identical to the solving process for the
reference point P in Section 6.2, it is not repeated here. Similarly, the value of the curvilinear coordinate θ of each point on the worm
dedendum is the same. Substituting the outcome of the curvilinear coordinates θ for the reference point P and the worm dedendum into
Table 1
Design parameters of face worm gear drive.
Nomenclature Symbol and formula Results (unit)
Center distance a 100 (mm)

Transmission ratio i12 53
Number of worm threads Z1 1
Number of worm gear teeth Z2= i12 Z1 53
Radius of worm pitch circle r1 ≈ 0.68a0.875 /2 20 (mm)
Modulus m ≈ 2a /i12 Z1 4 (mm)
Worm helix parameter p = mZ1 /2 2 (mm)
Worm axial tooth thickness on pitch circle sx1 = πm/2 6.283 (mm)
Worm thread length LW = 0.5a 50 (mm)
Radius of worm addendum circle ra1 = r1 + h∗a1 m, (h∗a1 = 1) 24 (mm)
Radius of worm dedendum circle rf1 = r1 − h∗f1 m, (h∗f1 = 1.25) 16 (mm)
Worm working tooth height hw1=2.25m 9 (mm)
Curvilinear coordinates of reference point P (uP /mm, θP /∘ , φP /∘ , φP1 /∘ ) i-flank (158 179.7, 454, 270.8)
e-flank (160, 269.7, 1774, 1781)
Coordinates of reference point P in σ (XP, YP, ZP) i-flank (0.23, -24, -25) (mm)
e-flank (-0.84, -23.99, -25) (mm)
Worm limit axial installation distance zL , (S = 1, 2), (mm)
(S) i-flank e-flank
48.8 45.7
Worm axial installation distance zA = kA a, (kA = 0.65) 65 (mm)
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
Radius of worm gear outer end 152 (mm)
ra2 = (zA + LW )2 + a2 ≈ 1.52a
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
Radius of worm gear inner end ) 119.46 (mm)
( LW 2
r2P = (XP + a)2 + ZP + zA +
2
Tooth width for face worm gear b2=kg•a (kg ≈ 0.35) 35 (mm)
Working tooth height for face worm gear hw2=1.75m 7 (mm)
17
Table 2
Operating parameters for machining worm rough.
Nomenclature Symbol and formula Results (unit)
Radius of grinding wheel rg 150 (º)

Lead angle of worm pitch circle γ = arctan(mZ1 /2r1 ) 5.71 (º)
Half taper angle of grinding wheel for i-flank δ(1)
g
65 (º)
Spin angle of grinding wheel for i-flank ε1 5 (º)
Half taper angle of grinding wheel for e-flank δ(2)
g
63 (º)
Spin angle of grinding wheel for e-flank ε2 -5 (º)
Operating center distance ad = rf1 + rg /cosεs , (mm) i-flank e-flank
166.6 166.6
Fig. 9. Curve fP (θ) of reference point P.
Eq. (63), the coordinates of the intersections between the worm tooth profile and the worm addendum and dedendum are acquired.
These outcomes are summarised in Table 3(a). After obtaining the curvilinear coordinates θ of the reference point P and the worm
dedendum, the worm tooth profile is drawn directly using the single parameter equation for the worm tooth profile in Eq. (63), as
shown in Fig. 10.
On the other hand, the boundary points E and I for the line of section are the intersection points between this line of section with the
inner and outer ends on the worm gear, respectively. Thereupon, the variable φ of these two intersection points should satisfy the
function φ(θ) in Eq. (57). Thus, by bringing the functions u(θ) in Eq. (47) and φ(θ) in Eq. (72) into the boundary equations for the inner
and outer ends of the face worm gear in Eq. (60), the single-dimensional nonlinear equations with θ can be obtained as
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ √̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
( )2
Worm gear inner end: fI (θ) = x22 + y22 − (XP + a)2 + ZP + zA + L2W , Worm gear outer end
18
Fig. 10. Worm axial tooth profile.
Table 3
(a) Numerical results of boundary points and key points for worm axial tooth profile and line of section.
i-flank, S=1, μ=-58.1º e-flank, S=2, μ=54.2
On worm axial tooth profile
Coordinates (u /mm, θ/∘ , φ/∘ , φ1 /∘ ) (xt , zt )/mm (u /mm, θ/∘ , φ/∘ , φ1 /∘ ) (xt , zt )/mm
Boundary points B1 (158, 179.7, -328, -509) (24, 2.3) (160, 269.7, 73, -104) (24, 3.8)
B2 (167, 179.2, -332, -512) (16, -2.3) (170, 269.2, 148, -28) (16, 8.8)
Key points PS (162, 179.4, -330, -510) (20, 0) (165, 269.4, 146, -31) (20, 6.28)
On line of section
(xo2 , yo2 )/mm (xo2 , yo2 )/mm
Boundary points E (162, 179.5, -1146, -1328) (98.7, 119) (164, 269.5, -428, -604) (102, 116)
I (162,179.4, 379, 200) (100, 66) (164, 269.5, 1038, 857) (100, 65)
Key points WS (162, 179.5, -450, -631) (99.1, 95) (164, 269.5, 263, 87) (101.6, 92)
(b) Numerical results of for worm axial tooth profile angle and helix angle at midpoint of line of section.
i-flank e-flank
Worm axial tooth profile angle, vS /∘ , (S = 1, 2) 29.9598 31.9787

Helix angle at midpoint of line of section, β(S)
wg / , (S = 1, 2)
∘ 48.0067 47.0172
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
( )2̅
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅
LW
fE (θ) = x22 + y22 − (XP + a)2 + ZP + zA + − kg ⋅ a (79)
2
From Fig. 11, the iterative initial values for Eq. (79) can be chosen reasonably. Then, the values of θ for two boundary points E and I can
be solved iteratively from Eq. (79). By bringing the values of θ for the points E and I into the equation of the line of section in Eq. (73),
the coordinates of two points E and I can be determined. Their outcomes are shown in Table 3(a).
After acquiring the curvilinear coordinates θ for the points E and I of the line of section, the line of section can be drawn directly on
the tooth profile of face worm gear using the equation of the line of section in Eq. (73), as shown in Fig. 11(c). The projection of the line
of section on the indexing plane is shown in Fig. 11(d).
(c) Line of section on tooth profile of face worm gear (d) Projection of line of section on the indexing plane for two flanks of one
tooth on worm gear tooth surfaces.
6.3.2. Worm axial tooth profile angle and helix angle at midpoint of line of section
The tooth profile angle for the intersection between the tooth profile line and the worm indexing circle is illustrated to explain the
calculation method of the tooth profile angle. Similar to the calculation of the curvilinear coordinates of the reference point P, using the
equation for the worm indexing circle, the single parameter non-linear equation about the curvilinear coordinate θ is derived from Eq.
(48). After determining the iterative initial value, the numerical results of the curvilinear coordinate θ of the points P1 and P2 can be
worked out by iteratively solving. The numerical results for the tooth profile angle can be obtained by taking θ of the points P1 and P2
into the equation for the tooth profile angle in Eq. (67). These calculation outcomes are included in Table 3(b).
In addition, to calculate the helix angle at a point on the line of section, the curvilinear coordinate θ for the point should first be
determined. Thus, by combining the equation for the ordinate of the point on the line of section with the equation of the line of section
in Eq. (73), a one-dimensional nonlinear equation with θ similar to that in Eq. (79) is obtained, which can be solved in the same way as
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
( )2 k ⋅a
Eq. (79). As shown in Fig. 6, when the point lies at the midpoint of the line of section, its ordinate is (XP + a)2 + ZP + zA + L2W + g2 .
After iteratively solving, the curvilinear coordinate θ of the midpoint can be obtained. The numerical results for the helix angle at the
midpoint of the line of section can be solved by bringing the θ of the midpoint into Eq. (78). These outcomes are included in Table 3(b).
Generally, Figs. 10 and 11(d) and the outcomes in Table 3 show that the geometry of the tooth surfaces on both flanks for the worm
pair is asymmetrical.
19
Fig. 11. (a) Curves fI (θ) and fE (θ) for convex flank. (b) Curves fI (θ) and fE (θ) for concave flank.
6.4. Global meshing performance for face worm gear drive
From Fig. 12, a three-dimensional diagram of the worm helicoid is drawn according to Eq. (19). The contact zones and the contact
lines are drawn on the worm helical surface.
To visually depict the conjugate situation of the face worm gear drive, the projection of the contact zones is plotted into the axial
cross-section of the worm pair illustrated in Figs. 13 and 14.
In the contact zones, PiPB1PC1PD1 is the contact region boundary for the i-flank and PA2PB2PC2PD2PE2 is the contact region boundary
for the e-flank. The notations 1 ~ 7 denote the contact lines. These contact lines are indicated by green lines. Since the contact lines can
be acquired from the interpolation of the points on them, the computation for the contact lines can be concluded as the computation for
the points on them. These points on the contact lines are represented by the " * " in Figs. 13 and 14. Their specific calculations will be
discussed later.
20
Fig. 12. Three-dimensional drawings of contact region and instantaneous contact lines on two flanks of worm helicoid.
Fig. 13. (a) Projection of contact region and instantaneous contact lines on axial section of worm helicoid. (b) Projection for conjugate region of
contact region and conjugate lines of instantaneous contact lines on face worm gear tooth surface.
Furthermore, Figs. 13 and 14 show that the rough for the face worm gear designed using the method in Section 4 can ensure that the
conjugate zone of the contact zone covers nearly the full tooth surface on the face worm gear. The actual meshing region of the worm
covers virtually the whole worm helicoid.
6.4.1. Calculation principle for boundary points of contact region

As shown in Figs. 13 and 14, the boundary points for the contact region on i-flank are the reference points P on i-flank, the
intersection point between the worm addendum and the worm outer end denoted as PB1, the intersection between the addendum and
the inner end for the face worm gear denoted as PC1, and the intersection between the addendum for the face worm gear and the worm
outer end denoted as PD1. Besides, the boundary points of the contact zone on the e-flank are: the point PA2 on the e-flank is the
intersection between the worm addendum and the inner end for the face worm gear, the intersection between the worm addendum and
the outer end for the face worm gear called PB2, the intersection between the addendum and the outer end for the face worm gear called
PC2, the intersection between the addendum for the face worm gear and the worm inner end called PD2, and the intersection between
the inner end for the face worm gear and the worm inner end called PE2.
According to Section 4.1, it is clear that the values of u and θ for the worm addendum are identical. Thus, once the curvilinear
coordinates uP and θP of the reference point P are solved, the motion parameters φ and φ1 of the boundary point PB1 for the i-flank and
21
Fig. 14. (a) Projection of contact region and instantaneous contact lines on axial section of worm helicoid. (b) Projection for conjugate region of
contact region and conjugate lines of instantaneous contact lines on face worm gear tooth surface.
the points PA2 and PB2 for e-flank can be calculated by employing φ1 (θ, φ) in Eq. (55), and the position equation of the outer ends for the
worm and face worm gear. The system of equations is
⎧
⎪ zo1 − LW /2
⎪
⎪ φPB1 (θ), φPB2 (θ) =
⎪
⎨ p C
√ ̅̅̅̅̅̅̅̅̅̅̅̅̅̅
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
( )2̅ , φ1 (θ, φ) = φ − φ0 − arcsin √̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ (80)
⎪
⎪ L A 2 + B2
⎪
⎪ 2 2 2 W
⎩ fPA2 (φ) = x2 + y2 − (XP + a) + ZP + zA + =0
2
Thereupon, substituting the numerical outcomes for uP and θP of the reference point P into φPB1 (θ), φPB2 (θ), and φ1 (θ, φ) in Eq. (80),
the curvilinear coordinates φ and φ1 at points PB1 and PB2 can be worked out. Whereas, the curvilinear coordinate φ for the point PA2
needs to be acquired by iteratively solving for fPA2 (φ) in Eq. (80). To find the iterative initial value, the curve for the function fPA2 (φ) is
plotted in Fig. 15(a). The intersection point (858º, 0) between the function fPA2 (φ) and the horizontal axis can be used as the iterative
initial value. The value of φ1 at the PA2 is solved by substituting the obtaining values of θ and φ into φ1 (θ,φ). The numerical outcomes
Fig. 15. (a) Curve fPA2 (φ) of boundary point PA2 for e-flank. (b) Curve of function fPE2 (θ) of boundary point PE2 for e-flank.
22
for the curvilinear coordinates for the points PB1, PA2, and PB2 are listed in Table 4.
Because the boundary point PE2 of the contact zone is the intersection of the inner ends for the worm and the worm gear, the
following equations system can be established as
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
( )2̅
√̅̅̅̅̅̅̅̅̅̅̅̅̅̅
LW
2
Φd (u, θ) = 0, Φ(u, θ, φ, φ1 ) = 0, zo1 − pφ = − LW / 2, fPE2 (u, θ, φ) = x2 + y2 − 2 2
(XP + a) + ZP + zA + (81)
2
Thus, by bringing the u(θ) in Eq. (47) and φ(θ) from the third equation in Eq. (81) into the fourth equation in Eq. (82), the function
fPE2 (θ) can be obtained and its image is plotted in Fig. 15(b).
After taking the coordinate (269.492º, 0) of the intersection between the function fPE2 (θ) and the horizontal axial line as the
iterative initial value, the value of θ is solved after iteration. The numerical results of curvilinear coordinates for PE2 are included in
Table 4.
In addition, the boundary points PC1, PC2, PD1, and PD2 of the contact zone are located at the worm gear addendum. Therefore, these
points can be obtained by using the computing steps of the boundary points for the line of section in Section 6.2. Their numerical
outcomes are listed in Table 4.
From the contact zone enclosed from these boundary points in Figs. 13 and 14, the effective working length of both flanks for the
worm helicoid can cover almost the entire worm helicoid. Although there is an asymmetry in the contact zone on both flanks for the
worm helicoid, this is not serious. In addition, from Figs. 13(b) and 14(b), the conjugate zone can cover almost the whole worm gear
tooth surface. However, the coverage of the conjugate zone on the concave flank of the face worm gear tooth surface is less than that on
the convex flank. This illustrates that it is impossible to ignore the asymmetry for the conjugate zone of the convex flank and concave
flank on the worm gear tooth surface.
Figs. 13(b) and 14(b) also illustrate that the design method presented in Section 4 can ensure that the dimension of the tooth surface
for the designed face worm gear is close to the coverage of the conjugate zone. Besides, it can also guarantee that the worm effective
working region covers nearly the whole worm helicoid. Therefore, this validates that the new estimating method for the size of the face
worm gear rough presented in Section 4 is reasonable.
6.4.2. Computation principle of key points on contact lines

Once the values of the meshing region boundary are identified, the scope of the worm rotation angle φ1 within a meshing cycle can
be obtained. The scope of φ1 for the worm i-flank is [-1277.7º, 123.02º] and the range of φ1 for the worm e-flank is [-639.4º, 917.2º].
Once an angle φ1 is determined, a contact line within the contact zone can be determined using the interpolation method [30].
Herein, six values of the angle φ1 for the two flanks can be selected evenly, depending on the ranges of [-1277.7º, 123.02º] and
[-639.4º, 917.2º]. These six values of φ1 corresponding to the six contact lines in the contact zone are employed to illustrate the
distribution pattern for the contact lines within the contact zone. Then, to draw a contact line, three key points are chosen at the
intersections between the contact line and the worm addendum, the worm pitch circle, and the worm gear addendum. These three key
points are named points 1, 2, and 3, respectively. Finally, these three key points are interpolated to obtain the corresponding contact
lines. The calculation method for these three key points is as follows.
Since contact point 1 is the intersection of the contact line with the worm addendum, the parameters u and θ for the contact point 1
should be equal to these of the reference point P. Thereupon, while given φ1 = − 133.7∘ to i-flank and φ1 = 496.6∘ to e-flank, a
nonlinear equation for the variable φ can be obtained using the meshing equation Φ = 0 in Eq. (31) as
C
f1 (φ) = φ − φ1 − φ0 − arcsin √̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ = 0 (82)
A2 + B 2
To solve this non-linear equation f1 (φ) = 0, the image of the function f1 (φ) is plotted in Fig. 16 taking the point 2-1 as an example.
From Fig. 16, the intersections are made between the curves of f1 (φ) and the horizontal axis. For the two flanks, they are (57.2º, 0) and
(673.5º, 0), respectively. Similarly, using Eq. (82), the values of φ for point 1 of the other five contact lines can be calculated in turn.
The numerical results for the curvilinear coordinates u, θ, φ, and φ1 at point 1 on the six contact lines are shown in Table 4.
Table 4
Numerical results for boundary points of meshing region.
(a) i-flank.
u/mm θ/º φ/º φ1 /º
PB1 157.59 179.66 -978.5 -1160.4

PC1 165.64 179.23 -1096 -1277.7
PD1 165.71 179.23 301.5 123.02
(b) e-flank.
u/mm θ/º φ/º φ1 /º
PA2 160.27 269.68 930.9 749.1
PB2 160.27 269.68 -463.3 -639.4
PC2 168.38 269.27 -338.2 -513.5
PD2 168.52 269.26 1096.3 917.2
PE2 163.91 269.49 1025.3 844.6
23
Fig. 16. Curves f1 (φ) for key point 2-1 on contact line 2.
Key point 2 is the intersection of the contact line with the worm pitch circle. According to Section 6.2, the points at the worm pitch
circle own the identical curvilinear coordinates u and θ, which are consistent with the characteristics of the points on the worm
addendum. Therefore, the computing method for point 2 is the same as point 1. These numerical results are shown in Table 4.
Key point 3 is the intersection between the contact line and the worm gear addendum. Thus, when given the value of φ1 , by
combining the grinding engagement equation Φd = 0 in Eq. (17), the meshing equation Φ = 0 in Eq. (31), and the worm gear
addendum equation y∗o1 = Yp + hw2 in Eq. (82), the nonlinear equation system concerning u, θ and φ to determine key point 3 is
established as
Φd = 0, Φ(u, θ, φ, φ1 ) = 0, y∗o1 = Yp + hw2 (83)
Because key point 3 is located at the worm gear addendum, the curvilinear coordinates φ of the points on the worm gear addendum is
represented as a function with θ when the abscissa HA = Yp + hw2 from Eq. (72). Thereupon, substituting the u(θ) in Eq. (47) and φL (θ)
in Eq. (72) into the meshing equation Φ = 0, a non-linear equation about the variable θ is acquired as
C
f3 (θ) = φ1 − φ(θ) + φ0 + arcsin √̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅ = 0 (84)
A2 + B2
Point 2-3 is taken here as an instance to describe the computation procedure of key point 3. As shown in Fig. 17, the intersection
points (179.23º, 0) for i-flank and (269.266º, 0) for e-flank between the function f3 (θ) and the horizontal axis are employed as an initial
value for f3 (θ) = 0. After iteration, the value of θ of the point 2-3 can be worked out. By substituting the value of θ to u(θ) in Eq. (47)
and φL (θ) in Eq. (72), respectively, the values of u and φ for point 2-3 can be obtained. Then, the coordinates of point 2-3 can be
determined by substituting the curvilinear coordinates u, θ, φ, and φ1 into Eqs. (19) and (32). The numerical results for the curvilinear
coordinates and coordinates of these key points are included in Table 4.
These results illustrate that the contact lines are uniformly spread over the worm and the face worm gear tooth surfaces, as shown in
Figs. 13 and 14. These contact lines and their conjugate lines are almost radial and sweep across the entire length of the tooth surfaces.
This ensures a larger value of the sliding angle between the two tooth surfaces for making the face worm gear drive easier to generate a
lubricating film and having good lubrication. In addition, because of the uniform distribution of contact lines in the meshing region,
the contact frequency is uniform and the contact stresses are evenly distributed.
6.5. Local meshing performance parameters
By substituting the numerical results in Table 4 into Eqs. (44) and (45), the induced principal curvature and the sliding angle at
each contact point can be obtained. Their numerical outcomes are presented in Table 5.
From Table 5, the induced principal curvature of the contact points on the two flanks of the worm tooth surfaces are all positive and
the direction for the normal vectors on the two flanks of the worm tooth surfaces point from space to solid. Thus, according to Ref. [42],
this demonstrates that no curvature interference is present in the meshing region for the two flanks of the worm tooth surfaces.
To reflect the induced principal curvature more visually, the nephogram of the numerical results for the induced principal cur
vature is plotted on the worm gear tooth surface with the basis of Table 5. Based on this, the varied range for the numerical results for
the induced principal curvature for the worm i-flank and the convex flank for the face worm gear is [0.0291mm− 1, 0.0458mm− 1]. The
variation scope of the induced principal curvature to the e-flank and the concave flank is [0.0088mm− 1, 0.0247mm− 1]. From Figs. 18
and 19, the induced principal curvature of the worm gear addendum and the worm inner end for the worm i-flank and the convex flank
24
Fig. 17. Curves f3 (θ) for key point 2-3 on contact line 2.
Table 5
Numerical results for key points on contact line.
(a) i-flank.
Contact lines ① ② ③ ④ ⑤ ⑥
φ1 /º 123 -133.7 -390.3 -647 -903.7 -1160.4

1 u/mm 157.59 - - - - -
θ/º 179.66 - - - - -
φ/º 302.6 46.5 -209.7 -465.9 -722.1 -978.5
k12
N /mm
− 1
0.035 0.0332 0.0318 0.0307 0.0298 0.0291
Ω/º 84.1 83.5 83.1 82.7 82.4 82.1
2 u/mm 162.23 - - - - -
θ/º 179.41 - - - - -
φ/º 302 46.1 -210 -466.1 -722.4 -978.6
k12
N /mm
− 1 0.0402 0.0381 0.0365 0.0353 0.0343 0.0335
Ω/º 82.1 81.5 81.0 80.5 80.2 79.8
3 u/mm 165.71 165.7 165.69 165.68 165.66 165.65
θ/º 179.2292 179.2298 179.2304 179.2312 179.2319 179.2325
φ/º 301.5 45.7 -210.3 -466.4 -722.5 -978.8
k12
N /mm
− 1 0.0458 0.0433 0.0414 0.0401 0.039 0.0382
Ω/º 79.9 79.2 78.7 78.2 77.8 77.5
(b) e-flank.
Contact lines ① ② ③ ④ ⑤ ⑥
φ1 /º 749.1 496.6 244.1 -8.4 -261 -513.5

1 u/mm 160.3 - - - - -
θ/º 269.7 - - - - -
φ/º 930.9 676.2 422.4 169 -84.2 -337.2
k12
N /mm
− 1 0.0088 0.0105 0.0119 0.013 0.0139 0.0146
Ω/º 67.1 72.8 75.6 77.04 77.9 78.5
2 u/mm 165 - - - - -
θ/º 269.44 - - - - -
φ/º 928.5 674.6 421.2 168.1 -84.9 -337.8
k12
N /mm
− 1 0.014 0.0158 0.0172 0.0182 0.019 0.0197
Ω/º 72.4 74.5 75.7 76.4 76.8 77.04
3 u/mm 168.49 168.46 168.43 168.41 168.39 168.38
θ/º 269.265 269.267 269.268 269.269 269.270 269.271
φ/º 927.3 673.8 420.6 167.6 -85.3 -338.2
k12
N /mm
− 1
0.0196 0.0213 0.0224 0.0234 0.0241 0.0247
Ω/º 72.8 73.9 74.5 74.9 75.1 75.2
and the worm gear addendum and the worm outer end for the e-flank and the concave flank are greater, whose values are 0.0458mm− 1
and 0.0247mm− 1, respectively. Based on the Hertzian equation [29], the contact stress level is higher around these two points.
The values of Table 5 also show that the range for the numerical results for the sliding angle of the worm i-flank and the convex
flank of the face worm gear is [77.5º, 84.1º], and for the e-flank and the concave flank is [67.1º, 78.5º]. To visually observe the
25
Fig. 18. (a) Nephogram of induced principal curvature on axial section of worm i-flank. (b) Nephogram of induced principal curvature on convex
flank of face worm gear tooth surface.
Fig. 19. (a) Nephogram of induced principal curvature on axial section of worm e-flank. (b) Nephogram of induced principal curvature on concave
flank of face worm gear tooth surface.
distribution for the values of the sliding angle on the tooth surface and to identify lubrication weaknesses, the nephogram for the
sliding angle is drawn on the worm and worm gear tooth surfaces. From Figs. 20 and 21, on the two flanks for the worm and face worm
gear, the values of the sliding angle are close to 90º, which indicates better circumstances for forming the lubricating oil film [42].
Furthermore, on the worm i-flank and the convex flank of the face worm gear, the position with a relatively smaller sliding angle is
located at the region close to the worm outer end and the worm gear addendum. On the e-flank and the concave flank, the position with
a relatively smaller sliding angle is near the reference point, which is the lubrication weakness point. In the vicinity of these two areas,
gluing failure is likely to occur. In addition, at other positions on the tooth surfaces, the sliding angle values are generally larger and the
circumstances for forming the lubricating oil film are better.
26
Fig. 20. (a) Nephogram of sliding angle on axial section of worm i-flank. (b) Nephogram of induced sliding angle on convex flank of face worm gear
tooth surface.
Fig. 21. (a) Nephogram of sliding angle on axial section of worm e-flank. (b) Nephogram of induced sliding angle on concave flank of face worm
gear tooth surface.
As shown in the nephograms in Figs. 18-21 and the data in Table 5, the local meshing performance of the novel face worm gear pair
is asymmetry. In comparison, the values of the sliding angle on the worm i-flank and the convex flank of the face worm gear are greater
but the induced principal curvature on the worm i-flank and the convex flank of the face worm gear is greater than the e-flank and the
concave flank. This means that the meshing between the i-flank and the convex flank has better lubrication properties but higher
contact stress levels than the meshing between the e-flank and the concave flank.
27
7. Conclusions
A novel face worm gear drive comprising a tapered surface enveloping cylindrical worm and a face worm gear is put forward. As the
worm can be precisely ground following the enveloping theory, this face worm gear drive is named the face worm gear drive with a
hardened cylindrical worm. The meshing theory of this novel face worm gear drive is systematically established. The meshing property
parameters are derived in the movable frame established on the worm gear tooth surface.
The meshing theory on the base of the reference point is further improved to the face worm gear drive, which covers three aspects.
First, using the meshing equation, the reference point can be strictly limited to the intersection of the worm addendum with the worm
inner end. On the basis of this, the boundary equation for the worm helicoid is established. Second, employing the meshing limit
equation and the curvilinear coordinates for the reference point, the worm limit installation distance can be obtained, which is used to
reasonably design the worm axial installation distance. This enables the meshing limit line away from the worm helicoid to ensure the
conjugation for the worm helicoid. Third, according to the characteristic that the indexing surfaces for the face worm gear pair are
cylindrical and planar, the design method of the rough dimension of the face worm gear is proposed. On this basis, the boundary
equations for the face worm gear tooth surface are established.
On the other hand, using the equations for the worm axial tooth profile and the line of section between the worm helicoid and the
indexing plane, the worm tooth profile line and the line of section are drawn. The worm axial profile angle and the helix angle at the
midpoint of the line of section are proposed as the evaluation parameters for assessing the asymmetry of the tooth surfaces.
The numerical results show that the meshing performances for this novel face worm gear drive are excellent. However, the meshing
performances of the two flanks of the tooth surfaces for this novel face worm gear pair are asymmetrical. This is mainly because the
geometrical shape of the two flanks of the tooth surfaces is asymmetrical. Using the proposed design methods for the rough dimension
of the face worm gear drive can ensure that the worm effective working region covers nearly the whole worm helicoid and the
conjugate zone for the meshing region can overlay nearly the whole worm gear tooth surface. This also validates that the introduced
design method is reasonable. Besides, the contact lines are evenly distributed on the tooth surfaces of the worm pair and the contact
frequency is uniform. In contrast, the meshing between the worm i-flank and the convex flank of the face worm gear has better
lubrication properties than the meshing between the e-flank and the concave flank but has a higher level of contact stress.
Declaration of Competing Interest
The authors declare that they have no known competing financial interests or personal relationships that could have appeared to
influence the work reported in this paper.
Data availability
Data will be made available on request.
Acknowledgment
This study was funded by the National Natural Science Foundation of China (52075083 and 52172401 and 52205069) and the
Open Fund of the Key Laboratory for Metallurgical Equipment and Control of Ministry of Education in Wuhan University of Science
and Technology (MECOF2021B02 and MECOF2020B03).
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Meshing Theory of Face Worm Gear Drive With Harden 2023 Mechanism and Machin

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Mechanism and Machine Theory 185 (2023) 105323

Contents lists available at ScienceDirect

Mechanism and Machine Theory

Meshing theory of face worm gear drive with hardened

2. Grinding engagement of tapered surface enveloping cylindrical worm

2.1. Establishment of coordinate systems

Fig. 3. Coordinate systems on tapered grinding wheel.

2.2. Geometrical parameters for generating tapered surface

2.3. Grinding engagement function and equation of worm helicoid

2.4. Characteristic parameters for grinding engagement

following the two principal directions (→

g22z (1) μ2 (1) μg2z

3. Meshing of face worm gear with hardened cylindrical worm

3.2. Meshing characteristics of face worm gear drive

(1) → → (1) → (1) →

Fig. 5. Projection of worm helicoid in axial section.

4.1. Reference point at worm helicoid and boundary equation of worm

The equations of the worm inner end and outer end:

4.2. Limit axial installation distance of worm

where the variable I(zA ) = zA + zo1 − pφ + L2W .

4.3. Boundary equations of face worm gear tooth surface

5. Evaluation parameters of asymmetry for two flanks of tooth surfaces

5.1. Worm axial tooth profile and tooth profile angles

where xt = x1 cosμ − y1 sinμ and yt = x1 sinμ + y1 cosμ.

xo1 tanμ + (yo1 + ad ) (2) xo1 tanμ + (yo1 + ad )

Substituting u(θ) in Eq. (47) and φ(S)

− [xo1 cosμ + (yo1 + ad )sinμ]φ }sinφand zt = zo1 − pφ .

Next, taking the derivative of φt (θ)(S = 1, 2) in Eq. (62) can yield

5.2. Geometry for line of section on worm gear tooth surface

Thus, using the trigonometric constant equation can yield

[HA B + (yo1 + ad )C]2 + (xo1 C + HA A)2 − (xo1 B − HA A)2

where the coefficients in Eq. (71) can be obtained as

the line of section can be acquired as

5.3. Helix angle of midpoint on line of section

After calculation, it can be derived from Eq. (70) as

nz xo1 and C = nz (a − i12 p).

Finding the derivative of φ(θ) in Eq. (72) yields

βwg at any point on the line of section can be solved as

difference between the absolute values of the helix angles β(S)

6. Numerical example and discussion

6.1. Main parameters of face worm gear drive

6.2. Calculation for reference point P

6.3. Computation of evaluation parameters of asymmetry

Center distance a 100 (mm)

Radius of grinding wheel rg 150 (º)

Fig. 9. Curve fP (θ) of reference point P.

Fig. 10. Worm axial tooth profile.

Worm axial tooth profile angle, vS /∘ , (S = 1, 2) 29.9598 31.9787

6.4. Global meshing performance for face worm gear drive

6.4.1. Calculation principle for boundary points of contact region

6.4.2. Computation principle of key points on contact lines

PB1 157.59 179.66 -978.5 -1160.4

6.5. Local meshing performance parameters

φ1 /º 123 -133.7 -390.3 -647 -903.7 -1160.4

φ1 /º 749.1 496.6 244.1 -8.4 -261 -513.5

Declaration of Competing Interest

Data will be made available on request.

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