Unit 2

Worm Gears
Syllabus
 Terminology
 Force Analysis ( Numerical) = 16 Marks

 Power Lost in Friction, Efficiency

 Worm and worm Gear Material

 Strength

A] Beam Strength ( Combine Numerical) = 16 Marks

B] Wear Strength
 Thermal Considerations ( Numerical) = 16 Marks

 Types of tooth failure in Worm Gear

 Methods of Lubrication
 Worm Gears- It consists of worm and worm wheel and used to
connect and transmit power between two non-intersecting and
perpendicular axes shafts.
 Compact
 High Speed Reduction 100:1
 Worm – Driver and having cylindrical form and resembles
trapezoidal or Acme treaded screw
 Worm Wheel -
 Advantages of -
◦ High Speed reduction, 100:1, Higher transmission ratio with less number of
gears.
◦ Can be designed to Self locking (When efficiency < 50 %)
◦ Comparatively less weight.
◦ Compact arrangement, less requirement of space.
◦ Noiseless operation
 Limitation
◦ Less efficiency.
◦ Friction generates heat.
◦ Worm teeth made up of brass or bronze , cost is high.
 Use –
◦ Material handling equipments , Steering mechanism, Gate valves Steering
mechanism in automobiles, Hoist and Lifts,
Terminology of Worm Drive
Terminology
Designation
1. Axial Pitch (Px) It is distance measured from a point on one
thread to the corresponding point on adjacent thread ,
measured on axis.
2. Lead (l)
Terminology
Terminology
Terminology
Que – In which Speed Reduction
is maximum in Single/ Double /
Triple start worm ?
Ans – Single
-Speed reduction inversely proportional to lead.
-Single start screw paired to 40 teeth worm , i =
40 means after 40 revolution of worm, worm-
wheel rotate once.
In two start worm paired to 40 teeth worm, i
= Z2/Zi = 20 means after 20 revolution of worm
worm-wheel rotate once.
 WORM PROPORTIONS
 Addendum of worm, h = m
a1
 Dedendum of worm, hf1 = m (0.2 cosϒ – 1)
 Clearance , c = 0.2 m cosϒ
 Addendum Diameter, d = m (q+2)
a1
 Dedendum Diameter, d = m (q+2-4.4 cosϒ)
f1
 WORM WHEEL PROPORTIONS

 Addendum, h = m (2 cosϒ -1)

a2
 Dedendum, hf2 = m (1 + 2 cosϒ)
 Throat (Addendum) Diameter, da2 = m (z2 + 4
cosϒ-2)
 Root Diameter, d = m (z – 2 - 0.4 cosϒ)
f2 2
 Face width of worm wheel,
 Length of root of worm wheel teeth , (l )
r
Force Analysis
 Problem. 2

Determine :
1] Force acting on Worm (Screw) and Worm Gear
2] Draw neat sketch and show all forces acting on Worm and Worm Gear
3] Efficiency.
4] Power lost in friction.
2 2
5] Rise in Temperature. Take= A= 3 m , k= 15 W/m C
[ Force (P) = Power/Velocity
Power = P x Velocity ]
Self Locking of Worm
Material Selection
 Worm- Case hardened Steel eg. 40C8
◦ Repetitive stress so criteria for material selection is
endurance strength.
 Worm wheel – Phosphor bronze
◦ Due to hobbing process limitations, Final shape gets
after some use .
◦ Soft material and cost is high.
Dissimilar materials are used to
1) Coeff. Of friction
2) Conformability of worm wheel w.r.t. worm is improved
Due to soft/weak material of worm wheel tooth is weak, so
worm wheel governs design procedure.
Strength Rating of Worm Gears
88888888
Beam
88
stre
0.48

0.25

40
1200
Wear Rating of Worm Gear
1200 0.112

0.26

6.315
Thermal Consideration
Thermal Consideration
Lubrication of Worm Gears
 Purpose:
To reduce possibility of scoring failure (Stick and Slip
phenomenon).
To reduce wear of teeth.
To reduce power loss.
Act as coolant to dissipating the heat.
To carry away worn out particles.
Prevent corrosion.
Lubrication of Worm Gears
 Lubricants used should have sufficient viscosity to
develop oil film and sustain it under loading
 Types of lubricants
Straight mineral oils:- It is medium duty gear lubricating oil. It
is used without additives.
Gear oils :- Heavy duty gears lubricated with gear oils. It is
having strong additives of EP (extreme pressure) type. Eg.
SAE75W, SAE80W, SAE90W upto SAE240W
Lubrication of Worm Gears
 Methods :
1. Splash Lubrication
2. Spray or Jet Lubrication (Extreme pressure lubrication)
Grease and drip lubrication method is not used in worm.
Types of Gear Tooth Failure
1. Bending Failure
2. Wear Failure
1. Pitting – Repetitive contact stress
2. Scoring – due to lack of lubrication , stick and slip
phenomenon
3. Abrasive wear – Particle trapped between teeth and thread
4. Corrosive wear – chemical action due to improper lubrication.
Discussion Points
 1} Why two dissimilar materials are used for worm and worm
wheel? Also state the commonly used material for worm and
worm wheeel?
 Ans : Practically worm wheel cannot be accurately generated in
the hobbing process. The final profile and finish of the worm
wheel teeth is the result of plastic deformation during the initial
stages of the service. Means the worm wheel must be soft
enough to get adjusted as per the worm. Hence it is necessary
to make the worm from the harder material and worm wheel
from the softer material, so that when they engage the worm
makes the required changes in the worm wheel profile.
 Generally the worm wheel is made up of Phosphor-bronze with
surface hardness about 100 BHN, whereas the worm (screw) is
made up of case hardened steels like 40C4 or 14C4.
 Explain the following terms for the worm & worm wheels.
 i) Diametral quotient
 ii) Self locking worm
 iii) Rubbing velocity
 Ans :
 Diameter quotient : Diametral quotient is the ratio of pitch
circle diameter of worm to the module of gear tooth .
 Self locking worm : Since worm is driver and worm wheel is
driven member and the reverse motion from the wheel to
worm is not possible hence it is called self locking worm. A
worm gear drive is called self-locking if the coefficient of
friction is greater than the tangent of lead angle.
 Rubbing velocity :Rubbing velocity is the relative velocity
between the worm and worm wheel. the coefficient of
friction is the function of the rubbing velocity. when the
rubbing velocity is higher there is less coefficient of friction.
The End