Requirement :

The wear free operation and low noise requirements from worm gear systems demands high
surface quality worm gears.

Rolling

Cold metal forming process

Blank material is displaced radially outward

Advantages

 No feed marks and scratch on the surface of the worm flank .

 Increased fatigue limit by 50% as no notches.
 Improved surface roughness.
 material waste reduced
 consumes less power

Gear / Worm rolling possibility

Work piece dia – starting min 5 mm

Work Piece length – max 200 (in feed type machines)
Module max 5.
The image below contains rolled parts.
Material Requirement

 Materials suitable for rolling typically need an elongation factor of at least 12%.
 Nearly all steels can be rolled.

Pre rolling diameter (PRE D)

This is the initial size of the black to be rolled and is calculated based on the following conditions and
the actual is arrived after iterations.

 Based on the material displacement which takes place during the process.
 Initial and final volumes are same

The table below indicated the pre rolling size for the mentioned parts :

Application FORD W601 QY

Platform 17W 14SW60 RW36 14SW60
OD 9.957 7.960 7.560 7.890
PCD 8.346 6.643 6.359 6.392
RD 6.081 4.810 4.600 4.420

PRE D 8.320 5.974 5.635 5.534

in mm
Requirement on part design

The images below contains the changes required in the parts to suit rolling. When rolling is
considered, the input shaft requires a step as mentioned. The size equals to the pre rolling diameter.

Rolling possibilities are

1. Shaft condition
2. Armature condition.

The better option can be choosen based on

1. Limitation while handling in house.

a. Study to be made based on the process flow, considering the factors like
i. operational load of various processes,
ii. Operator discipline in loading, unloading and handling,
iii. fixturing requirements
2. Supplier’s machine/tool design conditions.
Process flow 1

Worm
Production

Milling Rolling

The below mentioned suppliers are offering WORM GEAR ROLLING machines.

 KINEFAC
o KINEFAC DEEP WORM ROLLING OF POWER TRANSFER SHAFT
o WWW.KINEFAC.COM
o https://www.youtube.com/watch?v=r34NRPmoHRQ
 TESKER
o TESKER 440 WORM GEAR ROLLING
o WWW.TESKER.COM
o https://www.youtube.com/watch?v=P89Y4Ht7SCs
 CARPENTER TECH CORP
o Cold rolling Promet alloy into gear
o https://www.carpentertechnology.com/
o https://www.youtube.com/watch?v=7A2pQnjeY28
 TOBEST.CO
Process flow 2

worm
milling

super cold
grinding lapping
finishing rolling *

 The profile shape of worm is corrected. The other name “Burnishing”

Case Study

CEPS – Column type electric powered steering

Worm with plastic worm wheel used for low steering torque.

Location of this assy is close to cockpit. So noise to be avoided.

 Refer attached PDF “CEPS_Burnishing_of_Steering_Worms”

Supplier : Profiroll