CHAPTER 4 WORM GEAR Worm gears are used to transmit power between non-parallel shafts. The usual shaft angle is 90°. like member. Its mating gear is called worm gear. A worm and worm gear are used to provide a high angular velocity reduction. Worm gears sets are either single or double enveloping. A single enveloping worm gear set has a cylindrical worm with a throated gear wrapped around the worm. The double enveloping worm gear set has both members throated and wrapped around each other. The main difference between the two is that area of contact exists between the teeth of double enveloping gears and only line contact between those of single enveloping gears. The hand of helix is the same for both mating members.Worm gears are sometimes used where irreversibility in a mechanism is required. Irreversibility is possible when the lead angle is equal to or less than the static angle of friction. non-intersecting and The worm is a screw frat ich 2, 1 7 Lead engle 3 3 Worm gear Figure 4.1 [or] Scanned with CamScannerWorms commonly have only one tooth (or thread) and thus can create ratios as large as the number of teeth on the worm gear. This ability to provide high ratios in a compact package is one of the principle advantages of a wormset over other possible gearing configurations. Wormsets can be produced with ratios ranging from 3:1 to 100: 1. The number of threads on the worm is also referred to as its number of starts, A 2 or 3 start worm might be used for a low ratio wormset. The fig 1 shows the nomenclature ofa single enveloping worm gear. Materials for wormsets The worm is highly stressed and requires a hardened steel. The worm gear needs to be made from a material soft and compliant enough to run- in and conform to the hard worm under the high-sliding conditions. Sand cast, centrifugal-cast or forded bronze is typically used for the worm gear. Phosphor or tin bronze is used for high power applications and manganese bronze for small, slower-speed worms. Cast iron, soft steel, and plastics are sometimes used for lightly loaded, low-speed applications. Types of Worms The following are the two types of worms 1. Cylindrical or straight worm, and 2. Cone or double enveloping worm. Sale eeadot Double treaded, (0) Cyliniica on staight worm (6) Cone or double enveloping wom Figure 4.2 The cylindrical or straight worm, as shown in Fig. (2a), is most commonly used. The shape of the thread is involute helicoid of Leer, pressure angle 14 2 for single and double threaded ra Scanned with CamScannerworms and 20° for triple and quadruple threaded lc The cone or double envelo; ah but it requires extremely accu Types of Worm Gears ping worm sis used to some extent rate alignment There are 3 types of worms gears 1 Straight face worm gear, as shown in Fig. (4.3a), 2.Hobbed straight face worm gear, as shown in Fig. (4.3b), and. 3.Concave face worm gear, as shown in Fig. (430). sofia (a) Straight face. (b) Hobbed straight face. (c) Concave face, Figure 4.3 ‘The straight face worm gear is like a helical gear in which the straight teeth are cut with a form cutter. Since it has only point contact with the worm thread, it is used for light service. The hobbed straight face worm gear is used for light service but its teeth are cut with a hob, after which the outer surface is turned. The concave face worm gear is the accepted standard form and is used for heavy service and general industrial uses. The teeth of this gear are cut with a hob of the same pitch diameter as the mating worm to increase the contact area. Scanned with CamScannerTerms used in Worm Gearing s linear pitch of a worm. It is the axis of worm) from a he adjacent thread on 1.Axial pitch. (p,) It is also known a: distance measured axially ( parallel to the point on one thread to the corresponding point on U the worm. . 2.Lead. It is the linear distance through which a point on a thread moves ahead in one revolution of the worm. For single start threads, lead is equal to the axial pitch, but for multiple start threads, dead is equal to the product of axial pitch and number of starts. Mathematically Lead, l=p*n where px = Axial pitch ; and n = Number of starts. 3.Lead angle. It is the angle between the tangent to the thread helix on the pitch cylinder and the plane normal to the axis of the worm. tany= _ lead of the worm pitch circumference of the worm tany = 1 4.Normal pitch. It is the distance measured along the normal to the threads between two corresponding points on two adjacent threads of the worm. 5.Helix angle. It is the angle between the tangent to the thread helix on the pitch cylinder and the axis of the worm. It may be noted that the helix angle on the worm is generally quite large and that on the worm gear is very small. Thus, it is usual to specify the lead angle (y) on the worm and helix angle (B) on the worm gear. These two angles are equal for a 90° shaft angle. 6.Velocity ratio. It is the ratio of the speed of worm (m1) in r.p.m. to the speed of the worm gear (ng) in rp.m. Scanned with CamScanner_Proportions for Worms (DB table 12.25) Dimension Single &double Triple &quadruple threds Pitch diameter,zmm 2.40p.+28mm 2.40p,+28mm 7.54m+28mm 7.54m+28mm Face length,mm (4.5+0.02z1)px (4.5+0.02z1)p, (14.14+0.063z)m (14.14+0.063z;)m Addendum ,mm. 0.318px m 0.286px 0.9m Hub diameter,mm 1.66p,+25mm 1.726p¢+25mm 5.21m+25mm 5.425m+25mm Outside diameter of | d,+0.036p, dy+0.572p, weeme am y+2m dy+1.8m Proportions for Worm gears(D B 12.26) Dimension | Single &double _| Triple & quadruple threads outside dy+1.0135px dy#0.890p, diameter,mm | 4.43.1854m dy+2.7982m mm Face width, | 2.38p,+6.35mm 7.48m+6.35mm 2.15pc+5.08mm 6.758m+5.08mm Radius of | 0.882p,+14mm gear face,mM | 5 779m+14mm 0.914p+14mm 2.873m+14mm 7 Scanned with CamScannerRadius of | > apctldnian ( | 2.1pet 4mm pearirimsam | 6.915m+14mm 6.6m+14mm | Radius of — | 0.25p, — 0.25p. edgemm | 0.7858m 0.7858m Efficiency of Worm Gearing , The efficiency of worm gearing may be defined as the ratio of work done by the worm gear to the work done by the worm. Mathematically, the efficiency of worm gearing is given by _tany(I-w __tany) where y is the lead angle tany +m 7 jis coefficient of friction strength of worm gear teeth 1.In finding the tooth size and strength, it is safe to assume that the teeth of worm gear are always weaker than the threads of the worm. In worm gearing, two or more teeth are usually in contact, but due to uncertainty of load distribution among themselves it is assumed that the load is transmitted by one tooth only. According to Lewis equation .tangential tooth load F,=0,C,bY¥m where F,= Permissible tangential tooth load or beam strength of gear tooth, 64 = Allowable static stress, C\= Velocity factor, b = Face width, m= Module, and y = Tooth form factor or Lewis factor. 2.The dynamic tooth load on the worm gear is given by Fa= Fy x Cy 3.The static tooth load or endurance strength of the tooth F,=0,bYm ral Scanned with CamScanner4,The limiting or maximum load for wear is given by F, =d,bK where dp = Pitch circle diameter of the worm gear, b Face width of the worm gear, and K = Load stress factor (also known as material combination factor). The load stress factor depends upon the combination of materials used for the worm and worm gear. Forces acting on worm gear When the worm gearing is transmitting power, the forces acting on the worm are similar to those on a power screw. Fig. 4.4 shows the forces acting on the worm. It may be noted that the forces on a worm gear are equal in magnitude to that of worm, but opposite in direction ‘Worn gear ‘Worm gear shaft Worm gear Figures. 4 The various forces acting on the worm may be determined as follows 1. Tangential force on the worm, 2x Torque on worm Pitch circle diameter of worm (d1) = Axial force or thrust on the worm gear The tangential force (F,) on the worm produces a twisting moment of magnitude F, x (di / 2) and bends the worm in the horizontal plane, 2. Axial force or thrust on the worm, [a] Scanned with CamScannerF,= Fy /tany Tangential force on the worm gear = 2.x Torque ot diameter of worm gear (d2,) ial force on the worm tends to move the worm axially, induces an axial load on the bearings and bends the worm in a vertical plane with a bending moment of magnitude Fa x( d) / 2). 1. Radial or separating force on the worm, F,= Fa tana = Radial or separating force on the worm gear The radial or separating force tends to force the worm and worm gear out of mesh. This force also bends the worm in the vertical plane. Piteh circle ADVANTAGE AND DISADVANTAGE OF WORM GEAR DRIVE ADVANTAGE et and noiseless operation 2.high speed ratio with comparatively small overall dimension to the drive 3small size 4.irreversibility or the self-locking ability DISADVANTAGE low efficiency 2.low power capacity 3.intensive heating of the drive due to conversion of friction losses into thermal energy Design procedure 1.From table 12.7 obtain allowable static stresses %y for the given material 2.Calculate the speed and number of teeth on gears by using i =(ny/ng)=(22/21)=(do/dy) (* if the number of threads is not given assume it from table 12.28) 3. Find center distance ‘a’ DB 12.130a, 4.Findd, DB 12.103 Scanned with CamScannerby using the relation = ga itd 5.Find module m (use 12.97 Or 12.106) 6Find y lead angle D B12.100 TFind‘b’ DB 12.125 8.Calculate torque on worm gear element 2mM, 60 9.Find Fy DB 12.109 10.Find gear proportions from D B table 12.26 11. Find Cy =D BI12.108 12.Find Fydynamic load Fy x Cy 13.Find F, the dynamic strength DB 12.110 14 Find Fiy the limiting wear load. D B 12.122 use P= 15 Check F,2F, and F,>F,, are satisfied design is safe 16.If any condition is violated then do the following increase the face width -increase surface hardness by heat treatment -decrease the tooth error * ¢” 17. Draw figure of worm gear (D B page 208) if both conditions EXAMPLE PROBLEM AND UNIVERSITY QUESTIONS {Q1.Design a worm gear speed reducer to transmit 22K W at a worm speed of 1440 rpm the desired velocity ratio is 24:1 and an efficiency of at least 85% is desired. Assume that the worm is made of hardened steel and select suitable material of the gear giving the reason: (U@-2008) &(U Q 2006) A)given data P=22KW i!=(ny/m2) 24=(1440/n2) Scanned with CamScannern2=60rpm assume z1= 1 (_ D_B table 12.28 ) z=i'* 2, =1*24=24 17 P(KW) =0.02905 -"— DB 12.130a rot at? 24 +5 a=358.03mm round off to 360mm 22 = 0.0295 aos 1 466 q; DB 12.103 0875 d= 309 =117.66mm 1.466 round off to 120mm gehts 2 360 = 120442 2 4)=600mm. m=(dy/m) DB 12.97b =(600/24)=25 l=amz, DB12.98 =3.14*25*1=78.5mm tany =—— DB 12.100 : 85 fan7 = *120 [76] Scanned with CamScanneryHl19e° os bays DB 12.125 (2) 2 =86.25mm _2axnxM, 60 22000 = 27% 60% M, 60 M-=3503.18Nm, 2M,*K, j=—— DB 12.109 d, 2*3503180*1 ~ 600 =11677.26N Td yNy 1000*60 *600* 60 =1.884m/s D B 12.108 0.764 Dynamic load Fa =F, * Cy Fg =11677.26 * 0.764 =8921.75N F,=0,bYm DB 12.110 Y=ay where y=0.154-(0.912/z2) =100*86.25*0.364*25 =78487.5N Scanned with CamScannerF, = dybK D B 12.122 K=0.687 (D B table 12.31) =600"86.25*0.687 35550.25N the design is safe Since the conditions Fy >Fy_and Fs itch circle di Q2)A triple threaded worm has teeth of 6mm and pitch circle diameter of 50mm if the worm gear has 30teeth of 145 and the coefficient of friction of the worm gearing is 0.05 find I.the lead angle of the worm 2. velocity ratio 3.center distance and 4. efficiency (© Q 2007) A)Given data o=4t 2 m=6mm 4\=50mm 29-30 2-3 (lead angle of the worm I= amz, DB 12.98 =3.14*6*3=56.52mm L tany =—— Y DB 12.100 _ 56.52 a*50 =19.79° (ii) Velocity ratio zalz1 =(30/3)=10 (iii) Centre distance d=mz DB 12.97b Scanned with CamScanner=6*30 =180mm d,t+d, ae ar 50+180 2 =115mm. a= (iv) efficiency _ tan y(1— stan y) any +h DB12.117 _ tan19.79(1= 0.05 tan19.79) 94 »99 a tan 19.79 + 0.05 86.22% 703). worm drive transmits 1SKW at 2000rpm to a machine carriage a Fézpm. The worm is triple threaded and has 65mm pitch diameter. The ‘worm gear has 90 teeth of 6mm module. The tooth form is to be 20°FD jnvolute. The coefficient of friction between the mating teeth may be taken as 0.10. Calculate (i) tangential force acting on the worm (ii) axial thrust and separating force on the worm and (iii) efficiency of the worm (U Q 2007) drive A) given data P=15KW n,=2000rpm. ny=7Srpm 2022, WOT YP 273 d)=65mm 2-90 m=6mm o=20°FD 1=0.10 2axn, xM, a oem NE 60 Scanned with CamScanneroa 15000 = 27% 200% M, 60 Me71656Nmm-— Zrastereere (i)Tangential force analysis on the worm pa 2MetK ar Kj=1 (assume) Fe 2*71656*1 65 =2204.8N DB 12.169 (axial thrust and separating force on the worm l=amz, DB 12.98 =3.14*6*3=56.52mm. I tany =—— DB 12.100 Th _ 56.52 2*65 y=15.47° axial force F,-F/tany =(2204.8/tan1 5.47) =1966.44N radial or separating force F,=F, tana =7966.44 tan20° =2899.54N (iii) efficiency tan y(1 — satan = Earl sony) DB12117 tany +0 _ tan15.47(1—0.10tan 15.47) “ =71.49 4 tan15.47+0.10 ae [a] Scanned with CamScannerQ4)Design a worm gear drive to tra speed ratio is 30 and the center dist A)given data P=2KW n=1200rpm 1 a=160mm. insmit 2K W power at 1200rpm. The lance is 160mm i'=(n)/n) 30=(1200/n2) m=40rpm assume z= 1 (_ D B table 12.28) z= i'* 2, =1*30=30 0.875 d= B 12.103 “1466? 160°" "7466 round off to 60mm =57.87mm gaits 2 160 = 8044 2 d)=260mm m=(d2/z2) DB 12.97b =(260/30)=8.6 round off to Imm l=amz, DB 12.98 =3.14*9*1=28.26mm I tany = DB 12.100 Scanned with CamScanner28.26 7*60 tany = 7 =8.53° oss (5 } D B 12.125 os »(S } 2 =42.42mm pa 2X XM, 60 9000 = 27 40% M, M-=477707.7Nmm fp =2MtK DB 12.109 2 Ki=1 (assume) _2*477707.7*1 a 260 =3674.66N yo 1000* 60 _ 2 *260* 40 ~~ 1000* 60 Cae D B 12.108 6l+v 2s 6.140.544 Dynamic load Fy =F, * Cy =0.544m/s =0.918 Fy =3674.66* 0.918 =3373.6N F, =0,bYm DB 12.110 14*y — where y=0.154-(0.912/z2) =100*42.42*0.388*9 =14813.06N Scanned with CamScannerF< dybK DB 12.122 K=0.549 (DB table 1231) =260*42.42*0.549 =6055.03N Since the conditions Fy>Fy and F>Fy the design is safe Q5)A hardened steel worm rotating at 1200rpm transmits power to a phosphor bronze gear(og=100N/mm?) with transmission ratio 15:1. The center distance is 200mm. Determine the power input rating from the standpoint of strength A) given data nj=1200rpm i'=15 o4=100N/mm? a=200mm '=(n/n2) 15=(1200/n2) n2=80rpm Assume z\=2(_ D B table 12.28) a=il* 2, =2*15=30 0.875 a wet DB 12.103 4 1466 200°" =< =70.35mm 4 466 round off to 72mm a ge the 160 = 7 Dae 2 d)=328mm m=(do/2) DB 12.97b =(328/30)=10.93 round off to 11mm Scanned with CamScanneroars »-(¢ } DB 12.125 2 ors 4 = (200 2 =51.56mm ye myn 1000* 60 *308* = 7*328*80 _ 1 37 m/s 1000* 60 oes D B 12.108 6.1+v c =o = 0816 6.141.37 * p= tk DB 12.109 d, KelI(assume) M+ 17961.55 = 2 M*t 328 M, =2945690Nmm _2axn,xM, 60 p= 28 80%2945.69 - 60 =24.66KW Q6)Hardened steel worm rotates at 1440 rpm transmits 11.5KW to phosphor bronze gear with gear ratio 15. design the worm gear drive and draw the arrangement (U Q 2008) A)given data P=11.5KW n,=1440rpm Scanned with CamScanneri'=15 i!=(n)/n) 49 242(1440/n2) n2=96rpm asa 2=2( D Biable 12. 28 ) BV" 2 =2*15 =30 1 P(KW) =0.02905 = —* i 45 DB 12.130a u 11.5= 0.02952 — 1545 a=196.46mm round off to 200mm oss a d= Nearage DB 12.103 000" "1,466 round off to 72mm = 70.35mm get 2 Ned = 20( 2 4)=328mm m=(d2/z2) DB12.97b =(328/30)=10.933 round off toll [= amz, DB 12.98 =3.14*11*2=69.08mm T =— DB 12.100 tany =F _ 69.08 ‘any Ten y=16.99° Scanned with CamScannerans o-( 5 } DB 12.125 0.87: te 200°° 2 =51.56mm pa2tX XM, 60 1160 =22£96% Me 60 Me1144.50Nm pam tk, eames K-=I(assume) DB 12.109 _2*114450041 ‘ 328 =6978.69N dyn, _T*SBIO ¥=To90*60 ~ 1000*60 47S 6.1 os 108 ay DBR 6.1 C= —-0: Giseieea 0787 Dynamic load Fa =F, * Cv Fg =6978.69 * 0.787 =5492.22N Y=3.14*y — where y=0.154-(0.912/z2) A 5 =o,b¥m pB 12.110 =100*51.56*0.388*11 =22011.70N F,=4,bK py B 12.122 K=0.687 (DB table 12.31) =328*51.56*0.687 =11618.32N Since the conditions Fy >Fy and F,>Fg the design is safe [86] Scanned with CamScannerTHEROTICAL QUESTIONS Lwrite briefly on material to be us df “fly a sed f i 2discuss different types of worm a a 3.Discuss the proportions for y ; Worm gear 4.what is a worm gear drive? Give some of its 5.Expalin the advantage and disady: " 6.why is the centre distance worm and worm gear applications sadvantage of worm gear drive an Important parameter in the design of : r(* for a given velocity ratio there is a relation between centredistance ,leadangle , and normal lead & a graph is drawn’ (a/ln)’ v/s ‘y’.. The lowest point on the curve gives the lead angle for minimum value of a/l,. this value of a/l, represents the minimum center distance that can be used with a given lead angle ) UNSOLVED RPOBLEM 1. A speed reducer unit is to be designed for an input of 1.1 kW with a transmission ratio 27 The speed of the hardened steel worm is 1440 rpm. The worm wheel is to be made of phospnor bronze. The tooth form is to be 20° involute 2. Design a worm and worm gear for a speed reducer to deliver 32KW at a speed of 580 rpm of the worm. The velocity ratio is to be 26 . select suitable materials 3. Design a worm gear drive to transmit 2K W power at 1100 rpm . the speed ratio is 40 and the approximate center distance is 100mm, , ‘A quadruple threaded worm has teeth of 6mm and pitch circle = 1 diameter of 50mm if the worm gear has 40teeth of 1 and the coefficient of friction of the worm gearing is 0.10 find 1.the lead angle of the worm 2. velocity ratio 3.center distance and 4. efficiency Scanned with CamScanner