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Subject - Machine Design - : Topic - Worm Gears

Worm gears are used to transmit power between non-intersecting shafts at right angles. A worm gear set consists of a threaded worm and a toothed worm wheel that envelops the worm threads. Worm gears provide high speed reduction in a compact size and smooth, self-locking operation. However, they have low efficiency and power capacity compared to other gear types. Proper material selection and thermal management are important considerations for worm gear design and performance.

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Rohit Ghulanavar
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355 views28 pages

Subject - Machine Design - : Topic - Worm Gears

Worm gears are used to transmit power between non-intersecting shafts at right angles. A worm gear set consists of a threaded worm and a toothed worm wheel that envelops the worm threads. Worm gears provide high speed reduction in a compact size and smooth, self-locking operation. However, they have low efficiency and power capacity compared to other gear types. Proper material selection and thermal management are important considerations for worm gear design and performance.

Uploaded by

Rohit Ghulanavar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Subject - Machine Design -

Topic – Worm Gears


Worm Gears

Worm gear drives are used to transmit power between two non-
intersecting shafts, which are, in general, at right angles to each
other.

The worm gear drive consists of a worm and a worm wheel.

The worm is a threaded screw, while the worm wheel is a toothed


gear.

The teeth on the worm wheel envelope the threads on the worm
and give line contact between mating parts.
The advantages of worm gear drives are as follows:

 The most important characteristic of worm gear drives is their high


speed reduction. A speed reduction as high as 100 : 1 can be
obtained with a single pair of worm gears.

 The worm gear drives are compact with small overall dimensions,
compared with equivalent spur or helical gear drives having same
speed reduction.

 The operation is smooth and silent.

 Provision can be made for self locking operation, where the motion is
transmitted only from the worm to the worm wheel. This is
advantageous in applications like cranes and lifting devices.
The drawbacks of the worm gear drives are as
follows:
The efficiency is low compared with other types of
gear drives.
The worm wheel, in general, is made of phosphor
bronze, which increases the cost.

Considerable amount of heat is generated in worm


gear drives, which is required to be dissipated by a
lubricating oil to the housing walls and finally to the
surroundings.

The power transmitting capacity is low. Worm gear


drives are used for up to 100 kW of power
transmission.
TERMINOLOGY OF WORM GEARS

A pair of worm gears is specified and designated by four quantities in


the following manner:

z1/z2/q/m

where,
z1 = number of starts on the worm
z2 = number of teeth on the worm wheel

q = diametral quotient

m = module (mm)

The diametral quotient is given by,


Axial Pitch
The axial pitch (px) of the worm is defined as the distance measured
from a point on one thread to the corresponding point on the adjacent
thread, measured along the axis of the worm.
Lead

The lead (l) of the worm is defined as the distance that a point on the
helical profile will move when the worm is rotated through one
revolution.
Lead Angle
The lead angle (g) is defined as the angle between a tangent to the
thread at the pitch diameter and a plane normal to the worm axis.

Helix Angle
The helix angle (y) is defined as the angle between a tangent to the
thread at the pitch diameter and the axis of the worm.
Pressure Angle

The tooth pressure angle (a) is measured in a plane containing


the axis of the worm and it is equal to one-half of the thread
angle.

Single-enveloping Worm Gear Drive

 A single-enveloping worm gear set is one in which the gear


wraps around or partially encloses the worm.

 This results in line contact between the threads of the worm


and the teeth of the worm wheel.

 In this case, the worm is also called ‘cylindrical’ or


‘straight’ cylindrical worm.
Double-enveloping Worm Gear Drive

 A double- enveloping gear set is one in which the gear wraps


around the worm and the worm also wraps around the gear.

 This results in area contact between the threads of the worm and
the teeth of the worm wheel.

 In this case, the worm is also called ‘hourglass’ worm. This drive is
also called ‘cone’ gearing.

Advantages
 The contact pressure between the threads of the worm and the
teeth of the worm wheel is low. This reduces wear.

 The drive occupies less space for a given capacity.


FORCE ANALYSIS

The analysis of three components of the resultant tooth force


between the meshing teeth of worm and worm wheel is
based on the following assumptions:

The worm is the driving element, while the worm wheel is


the driven element.

The worm has right-handed threads.

The worm rotates in anti-clockwise directions as shown in Fig

The three components of the gear tooth force between the


worm and the worm wheel are shown in Fig.
FRICTION IN WORM GEARS

It has been observed that the coefficient of friction in worm


gear drives depends upon the rubbing speed. The rubbing
speed is the relative velocity between the worm and the wheel.
In this velocity triangle,

V1 = pitch line ve1ocity of the worm (m/s)

V2 = pitch line velocity of the worm


wheel (m/s)

Vs = rubbing velocity (m/s)


SELECTION OF MATERIALS

• The threads of the worm are subjected to fluctuating stresses and


the number of stress cycles is fairly large.

• Therefore, the surface endurance strength is an important criterion


in the selection of the worm material.

• The core of the worm should be kept ductile and tough to ensure
maximum energy absorption.

• The worms are, therefore, made of case hardened steel with a


surface hardness of 60 HRC and a case depth of 0.75 to 4.5 mm.
The following varieties of steel are used for the worm:

• Normalized carbon steels—40C8, 55C8

• Case-hardened alloy steels–16Ni80Cr60, 20Ni2Mo25

• Case-hardened carbon steels—10C4, 14C6

• Nickel–chromium steels—13Ni3Cr80, 15Ni4Cr1

• The worm wheel material should be soft and


conformable.
• Phosphorbronze, with a surface hardness of 90–120 BHN, is
widely used for the worm wheel.

• Phosphor-bronze worm wheels are sand-cast, sand-cast and


chilled, or centrifugally cast.

• Phosphor-bronze is costly and in case of worm wheels with large


dimensions, only the outer rim is made of phosphor-bronze.

There are two reasons for using ‘dissimilar’ or


‘heterogeneous’ materials for worms and worm wheels:

i) The coefficient of friction is reduced.

ii) The conformability of worm wheel with respect to the worm


is improved.
STRENGTH RATING OF WORM GEARS

The worm gears are usually designed according to national and


international codes.

There are two basic equations: beam strength and wear strength
equations.
The maximum permissible torque that the worm wheel can withstand
without bending failure is given by the lower of the following two values
where,

(Mt )1, (Mt )2 = permissible torque on the worm wheel (N-mm)

Xb1, Xb2 = speed factors for strength of worm and worm wheel

Sb1, Sb2 = bending stress factors of worm and worm wheel

m = module (mm)

lr = length of the root of worm wheel teeth (mm)

d2 = pitch circle diameter of worm wheel (mm)

g = lead angle of the worm


WEAR RATING OF WORM GEARS

The maximum permissible torque that the worm wheel can withstand
without pitting failure, is given by the lower of the following two values:
The values of the surface stress factor (Sc) for the various materials are
given in Table 20.3.
The values of the worm gear zone factor are given in Table 20.4.
The speed factors (Xc) for wear depend upon the rotational speed and the
rubbing speed Vs.
THERMAL CONSIDERATIONS

The efficiency of a worm gear drive is low and the work done by friction is
converted into heat. When the worm gears operate continuously,
considerable amount of heat is generated.

The rate of heat generated (Hg ) is given by


Thank You

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