Worm Gears

DESIGN OF MECHANICAL SYSTEM

Contents
Terminology
Proportions of Worm Gears
Force Analysis
Friction in Worm Gears
Selection of Materials
Strength Rating of Worm Gears
Wear Rating of Worm Gears
Thermal Considerations
The worm is, in effect, a helical gear with a helix angle so large that a
single tooth wraps continuously around its circumference.
The worm is analogous to a screw thread and the worm gear is
analogous to its nut.

A Single Enveloping
Worm set
Worm Gears Application
Example
Terminology
Terminology
Proportions of Worm Gears
Proportions of Worm Gears
Face Width

𝑙𝑟 =( 𝑑𝑎 1 +2 𝑐 ) sin
−1
[ 𝐹
( 𝑑𝑎 1 +2 𝑐 ) ]
Force Analysis
Components of Tooth Force Direction of Force Components
Force Analysis
Components of Tooth Force
Friction in Worm Gears
Components of Frictional Force
Friction in Worm Gears
 Coefficient of friction  depends on the
rubbing speed.
 Rubbing speed is the relative velocity
between the worm and worm wheel.
 Pitchline velocity for worm, V1
d1n1
V1 
60 1000

 From velocity
V triangle
d n
Vs  1
 1 1
cos  60000  cos 
Velocity of Sliding
 Friction in Worm Gears
Coefficient of Friction for Worm Gears
Variation of coefficient
of friction with respect
to rubbing velocity is
shown in adjoining
graph.
Efficiency of Worm Gear
Drive
Efficiency of drive n2 1

Power Output n1 i

Power Input

P2 t  d 2  n2 P   i tan  P   tan 

 2  1a  1a
P1 t  d1  n1 P1 t  i P1 t
2
Pcos  cos    sin   tan  cos    tan  
 
Pcos  sin    cos   cos    cot  
Use
cos    tan  z2
 d 2 mz 2 z 2 z1
cos    cot  
d1 mq
 
q q
 i tan 
z1
Efficiency of Worm Gear
Drive
Efficiency of worms gears is low and varies
considerably in the range of 50 to 90 %
In general, the efficiency is inversely proportional to
speed ratio, provided the coefficient of friction is
constant.
Strength Rating of Worm
Gears…

where,
Mt- Permissible torque
Sb- Bending stress factor Power transmitting capacity
Xb- Speed factor for strength based on beam strength
lr- Length of root of the worm wheel teeth 2nM t
d2- diameter of worm wheel kW 
60  10 6
- Lead angle
m- Module
 Strength Rating of Worm
Gears…

Bending stress factor

 Strength Rating of Worm
Gears…
Speed factor for Worm Gears for Strength (Xb)

Speed factor
Wear Rating of Worm Gears

where,
Mt- Permissible torque
Sc- Surface stress factor Power transmitting capacity
Xc- Speed factor for wear based on beam strength
Yz – Zone factor 2nM t
d2- diameter of worm wheel kW 
60  10 6
m- Module
 Wear Rating of Worm
Gears…
Values of the Surface Stress Factor, Sc

Surface
Stress Factor
 Wear Rating of Worm
Gears…
Values of zone factor Yz
z1 q=8 q=9 q = 10 q = 12 q = 16 q = 20
1 1.084 1.128 1.143 1.202 1.374 1.508
2 1.114 1.214 1.231 1.280 1.418 1.575
Zone Factor 4 1.204 1.380 1.460 1.515 1.634 1.798
Speed factor for Worm Gears for Wear, (Xc)
Selection of Materials
Numerical Example
A pair of worm and worm wheel is designated as 1/30/10/10. The input
speed of the worm is 1200 rpm. The worm wheel is made of
centrifugally cast, phosphor bronze and the worm is made of case
hardened carbon steel 14C6. Determine the power transmitting
capacity based on the beam strength.
Given:
z1= 1, z2 = 30, q = 10, m = 10, n1 = 1200 rpm
i = z2/ z1=30
n2 = 1200/i =40 rpm, d2 = m z2 = 10 (30)= 300
tan  = z1/q = 0.1, hence  = 5.71
Numerical Example (contd)
Facewidth,
Clearance, c =0.2 m cos 
da1= m (q+2) =

Read Sb1 and Sb2 from table

Read Xb1and Xb2 from graph
Use torque equation to find lower torque of the two.
 Thermal Considerations
 Rate of heat generated ,
H g  1000(1   ) PkW ...................................(1)
 The rate of heat dissipated,
H d  K (t  t0 ) A.....................................(2)
 Equating equations (1) and (2)
1000(1   ) PkW  K (t  to ) A...............................(3)
and we get
K (t  to ) A Power transmitting capacity based on
PkW 
1000(1   ) thermal considerations
Alternatively,
1000(1   ) PkW Resultant temperature of the lubricating
t  to 
KA oil for given power transmitting capacity
Example 20.6 Page
A pair of worm gears is designated as 1/40/10/4. The input speed of worm shaft
is 1000 rpm. The gear box has an effective surface area of 0.25 m 2. A fan is
mounted on the worm shaft to circulated air over the surface of the fins. The
coefficient of heat transfer can be taken as 25 W/m2C. The permissible
temperature rise of the lubricant oil above the atmospheric temperature is
45C. The coefficient of friction is 0.35 and the normal pressure angle is 20.
Calculate the power transmitting capacity base on thermal considerations.

Given:
K (t  to ) A cos    tan  z1
t-to = 45 PkW   tan  
1000(1   ) cos    cot  q
Answer: Power transmitting capacity based on thermal considerations is 1.026
kW