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Design & Calculate Worm Gear
Design & Calculate Worm Gear
Design & Calculate Worm Gear
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Worm Gears
Introduction..... Nomenclature..... Design Parameters..... Specifications..... Designation..... Worm Gear Profiles..... Materials..... Backlash/quality..... Design Process.....
Thermal Design..... Worm Gear Formulue..... Friction Factors..... Efficiency..... Self Locking..... Strength Design to BS721..... Strength Design to AGMA.....
Introduction
A worm gear is used when a large speed reduction ratio is required between crossed axis shafts which do not intersect. A basic helical gear can be used but the power which can be
transmitted is low. A worm drive consists of a large diameter worm wheel with a worm screw meshing with teeth on the periphery of the worm wheel. The worm is similar to a screw and
the worm wheel is similar to a section of a nut. As the worm is rotated the wormwheel is caused to rotate due to the screw like action of the worm. The size of the worm gearset is
generally based on the centre distance between the worm and the wormwheel.
If the worm gears are machined basically as crossed helical gears the result is a highly stress point contact gear. However normally the wormwheel is cut with a concave as opposed to
a straight width. This is called a single envelope worm gearset. If the worm is machined with a concave profile to effectively wrap around the wormwheel the gearset is called a double
enveloping worm gearset and has the highest power capacity for the size. Single enveloping gearsets require accurate alignment of the worm-wheel to ensure full line tooth contact.
Double enveloping gearsets require accurate alignment of both the worm and the wormwheel to obtain maximum face contact.
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The double enveloping (double throat/double globoid ) option is the most difficult to manufacture and set up. However this option has the highest load capacity, near zero backlash
capability, highest accuracy and extended life capability.
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A more detailed view showing a cylinderical worm and an enveloping gear. The worm is shown with the worm above the wormwheel. The gearset can also be arranged with the worm
below the wormwheel. Other alignments are used less frequently.
Nomenclature
As can be seen in the above view a section through the axis of the worm and the centre of the gear shows that , at this plane, the meshing teeth and thread section is similar to a spur
gear and has the same features
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M 2 = Worm wheel torque (Nm)
n 1 = Rotational speed of worm (revs /min)
n 2 = Rotational speed of wormwheel (revs /min)
p x = Axial pitch of of worm threads and circular pitch of wheel teeth ..the pitch between adjacent threads = π. m. (mm)
p n = Normal pitch of of worm threads and gear teeth (m)
q = Worm diameter factor = d 1 / m - (Allows module to be applied to worm ) selected from (6 6,5 7 7,5 8 8,5 9 10 11 12 13 14 17 20 )
p z = Lead of worm = p x. z 1 (mm).. Distance the thread advances in one rev'n of the worm. For a 2-start worm the lead = 2 . p x
R g = Reduction Ratio
μ = coefficient of friction
η= Efficiency
Vs = Worm-gear sliding velocity ( m/s)
z 1 = Number of threads (starts) on worm
z 2 = Number of teeth on wormwheel
Worm gears provide a normal single reduction range of 5:1 to 75-1. The pitch line velocity is ideally up to 30 m/s. The efficiency of a worm gear ranges from 98% for the lowest ratios to
20% for the highest ratios. As the frictional heat generation is generally high the worm box must be designed disperse heat to the surroundings and lubrication is an essential
requirement. Worm gears are quiet in operation. Worm gears at the higher ratios are inherently self locking - the worm can drive the gear but the gear cannot drive the worm. A worm
gear can provide a 50:1 speed reduction but not a 1:50 speed increase....(In practice a worm should not be used a braking device for safety linked systems e.g hoists. . Some material
and operating conditions can result in a wormgear backsliding )
The worm gear action is a sliding action which results in significant frictional losses. The ideal combination of gear materials is for a case hardened alloy steel worm (ground finished)
with a phosphor bronze gear. Other combinations are used for gears with comparatively light loads.
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Specifications
Very simply a pair of worm gears can be defined by designation of the number of threads in the worm ,the number of teeth on the wormwheel, the diameter factor and the axial module i.e
z1,z2, q, m .
This information together with the centre distance ( a ) is enough to enable calculation of and any dimension of a worm gear using the formulea available.
The sketch below shows the normal (not axial) worm tooth profile as indicated in BS 721-2 for unit axial module (m = 1mm) other module teeth are in proportion e.g. 2mm module teeth
are 2 times larger
Typical axial modules values (m) used for worm gears are
0,5 0,6 0,8 1,0 1,25 1,6 2,0 2,5 3,15 4,0 5,0 6,3 8,0 10,0 12,5 16,0 20,0 25,0 32,0 40,0 50,0
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A worm gear set normally includes some backlash during normal manufacture to allow for expansion of the gear wheel when operating at elevated temperaturs. The backlash is
controlled by adusting the gear wheel tooth thickness.
BS 721 includes a table of backlash limits related to the accuracy grade. The standard lists 5 accuracy grades.
Grade 1 relates to critical applications where minimum backlash is required i.e instruments /metering
Grade 2 relates to precision drives such as machine tools
Grade 3,4,5 relates to industrial drives with working temperatures of about 120o C
1) Initial information generally Torque required (Nm), Input speed(rpm), Output speed (rpm).
2) Select Materials for worm and wormwheel.
3) Calculate Ratio (R g)
4) Estimate a = Center distance (mm)
5) Set z 1 = Nearest number to (7 + 2,4 SQRT (a) ) /R g
6) Set z 2 = Next number < R g . z 1
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7) Using the value of estimated centre distance (a) and No of gear teeth ( z 2 ) obtain a value for q from the table below. (q -value selection)
8) d 1 = q.m (select) ..
9) d 2 = 2.a - d 1
10) Select a wormwheel face width b a (minimum =2*m*SQRT(q+1))
11) Calculate the permissible output torques for strength (M b_1 and wear M c_1 )
12) Apply the relevent duty factors to the allowable torque and the actual torque
13) Compare the actual values to the permissible values and repeat process if necessary
14) Determine the friction coefficient and calculate the efficiency.
15) Calculate the Power out and the power in and the input torque
16) Complete design of gearbox including design of shafts, lubrication, and casing ensuring sufficient heat transfer area to remove waste heat.
Worm gears are often limited not by the strength of the teeth but by the heat generated by the low efficiency. It is necessary therefore to determine the heat generated by the gears =
(Input power - Output power). The worm gearbox must have lubricant to remove the heat from the teeth in contact and sufficient area on the external surfaces to distibute the generated
heat to the local environment. This requires completing an approximate heat transfer calculation. If the heat lost to the environment is insufficient then the gears should be adjusted (more
starts, larger gears) or the box geometry should be adjusted, or the worm shaft could include a fan to induced forced air flow heat loss.
Formulae
Rg=z2/z1
eg a 30 tooth wheel meshing with a 2 start worm has a reduction of 15
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F wt = F ga = 2.M 1 / d 1
M 2 = F gt* d 2 / 2
Relationship between the Worm Tangential Force F wt and the Gear Tangential force F gt
V p = 0,00005236,d 2. n 2
Friction Coefficient
Note: The values of the coeffient of friction as provided in the table below are based on the use of phosphor bronze wormwheels and case hardended , ground and polished steel worms ,
lubricated by a mineral oil having a viscosity of between 60cSt, and 130cSt at 60 deg.C .
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Cast Iron and Phosphor Bronze .. Table x 1,15
Cast Iron and Cast Iron.. Table x 1,33
Quenched Steel and Aluminum Alloy..Table x 1,33
Steel and Steel..Table x 2
Friction coefficients - For Case Hardened Steel Worm / Phos Bros Wheel
The efficiency of the worm gear is determined by dividing the output Torque M2 with friction = μ by the output torque with zero losses i.e μ = 0
First cancelling [( M 1. d 2 / d 1 ) / M 1. d 2 / d 1 ) ] = 1
Denominator = [(cos α n / (cos α n . tan γ ] = cot γ
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Self Locking
Referring to the above graph , When the gear wheel is driving the curve points intersecting the zero efficiency line identify when the worm drive is self locking i.e the gear wheel cannot
drive to worm. It is the moment when gearing cannot be moved using even the highest possible torque acting on the worm gear. The self-locking limit occurs when the worm lead
angle ( γ ) equals atan (μ). (2o to 8o )
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It is often considered that the static coefficient of friction is most relevant as the gear cannot be started. However in practice it is safer to use the, lower, dynamic coefficient of friction as
this comes into play if the gear set is subject to vibration.
Note: For designing worm gears to AGMA codes AGMA method of Designing Worm Gears
The information below relates to BS721 Pt2 1983 Specification for worm gearing � Metric units. BS721 provides average design values reflecting the experience of specialist gear
manufacturers. The methods have been refined by addition of various application and duty factors as used. Generally wear is the critical factor..
The permissible torque (M in Nm) on the gear teeth is obtained by use of the equation
X b.2 = speed factor for bending (Worm wheel ).. See Below
σ bm.2 = Bending stress factor for Worm wheel.. See Table below
l f.2 = length of root of Worm Wheel tooth
d 2 = Reference diameter of worm wheel
m = axial module
γ = Lead angle
The permissible torque (M in Nm) on the gear teeth is obtained by use of the equation
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This is a metric conversion from an imperial formula..
X b.2 = speed factor for bending = 0,521(V) -0,2
The table below is derived from a graph in BS 721. I cannot see how this works as a small worm has a smaller diameter compared to a large worm and a lower speed which is not
reflected in using the RPM.
Additional factors
The formula for the acceptable torque for wear should be modified to allow additional factors which affect the Allowable torque M c
M c2 = M c. Z L. Z M.Z R / K C
The torque on the wormwheel as calculated using the duty requirements (M e) must be less than the acceptable torque M c2 for a duty of 27000 hours with uniform loading. For loading
other than this then M e should be modified as follows
M e2 = M e. K S* K H
Thus
uniform load < 27000 hours (10 years) M e ≤ M c2
Other conditions M e2 ≤ M c2
Lubrication (Z L)..
Z L = 1 if correct oil with anti-scoring additive else a lower value should be selected
Lubricant (Z M)..
Z L = 1 for Oil bath lubrication at V s < 10 m /s
Z L = 0,815 Oil bath lubrication at 10 m/s < V s < 14 m /s
Z L = 1 Forced circulation lubrication
Surface roughness (Z R ) ..
Z R = 1 if Worm Surface Texture < 3μ m and Wormwheel < 12 μm
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else use less than 1
Starting factor (K S) ..
K S =1 for < 2 Starts per hour
=1,07 for 2- 5 Starts per hour
=1,13 for 5-10 Starts per hour
=1,18 more than 10 Starts per hour
Speed Factors
X c.2 = K V .K R
Note: This table is not based on the graph in BS 721-2 (figure 7) it is based on another more easy to follow graph. At low values of sliding velocity and RPM it agrees closely with BS
721. At higher speed velocities it gives a lower value (e.g at 20m/s -600 RPM the value from this table for X c.2 is about 80% of the value in BS 721-2
Stress Factors
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Phosphor Bronze
69 8,3 8,3 9,0 15,2
Centrifugal cast
Phosphor Bronze
63 6,2 6,2 6,9 12,4
Sand Cast Chilled
Phosphor Bronze
49 4,6 4,6 5,3 10,3
Sand Cast
Grey Cast Iron 40 6,2 4,1 4,1 4,1 5,2
0,4% Carbon steel 138 10,7 6,9
0,55% Carbon steel 173 15,2 8,3
Carbon Steel
276 48,3 30,3 15,2
(Case hardened)
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13 1,784 1,806 1,898 1,998
14 1,811 1,9 2
Duty Factor
KH
Expected life
Impact from Prime mover Impact From Load
hours
Uniform Load Medium Impact Strong impact
1500 0,8 0,9 1
Uniform Load 5000 0,9 1 1,25
Motor Turbine Hydraulic motor 27000 1 1,25 1,5
60000 1,25 1,5 1,75
1500 0,9 1 1,25
Light impact 5000 1 1,25 1,5
multi-cylinder engine 27000 1,25 1,5 1,75
60000 1,5 1,75 2
1500 1 1,25 1,5
Medium Impact 5000 1,25 1,5 1,75
Single cylinder engine 27000 1,5 1,75 2
60000 1,75 2 2,25
The table below allows selection of q value which provides a reasonably efficient worm design. The recommended centre distance value "a" (mm)is listed for each q value against a
range of z 2 (teeth number values). The table has been produced by reference to the relevant plot in BS 721
Example
If the number of teeth on the gear is selected as 45 and the centre distance is 300 mm then a q value for the worm would be about 7.5
Important note: This table provides reasonable values for all worm speeds. However at worm speeds below 300 rpm a separate plot is provided in BS721 which produces more accurate
q values. At these lower speeds the resulting q values are approximately 1.5 higher than the values from this table. The above example at less than 300rpm should be increased to
about 9
Table of Center distances "a" relating to q values and Number of teeth on Worm gear z 2
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8.5 28 90 130 130 180 220 280 350 420 500 600 700
9 40 70 100 130 170 220 280 330 400 450 520
9.5 25 50 70 100 120 150 200 230 300 350 400
10 26 55 80 100 130 160 200 230 270 320
11 25 28 55 75 100 130 150 180 220 250
12 28 45 52 80 100 130 150 100
13 27 45 52 75 90 105
The AGMA method is provided here because it is relatively easy to use and convenient- AGMA is all imperial and so I have used conversion values so all calculations can be completed
in metric units..
Good proportions indicate that for a centre to centre distance = C the mean worm dia d 1 is within the range
Imperial (inches)
The formula will result in a life of over 25000 hours with a case hardened alloy steel worm and a phosphor bronze wheel
C s = Materials factor
b a = Effective face width of gearwheel = actual face width. but not to exceed 0,67 . d 1
C m = Ratio factor
C v = Velocity factor
σ a = W t / ( p n. b a. y )(N)
W t = Worm gear tangential Force (N)
y = 0,125 for a normal pressure angle α n = 20o
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γ = worm lead angle at mean diameter
α n = normal pressure angle
V s = π .n 1. d 1 / (60,000 )
T G = W t .d 1 / 2000
H loss = P in ( 1 - η )
C s values
C s (Chilled cast gears ) = 1000 for d 1 ≤ 200 mm ...else ... 2052 -456 log (d 1 )
C s (Centrifugally cast gears ) = 1000 for d 1 ≤ 635 mm ...else ... 1503 - 180 log (d 1 )
C m values
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C v values
f values
f (V s = 0) = 0,15
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