Design of Worm Gear System

1ST DRAFT (DEC. 2004)

BY
M. ABD-RABOU AND H. BOGIS
Mech. Systems Design and Prod. Dept., King Abdulaziz University

A Procedure to Design The Worm Gear System

1. Select the center distance (a) according to the following equation:

T2
a =750* 3 (1)
σC2

Where:
T2 is the applied torque on gear (in Nm)
σc is gear material contact strength (in MPa).
Recommended material for Gear is Bronze (Gz Cu Sn 12 DIN 17662)
with σc ≈ 480 MPa

2. Select the diameter of the worm as

d1=(0.3 to 0.5) * a (2)

3. Calculate the gear diameter as

d 2 = 2a − d1 (3)

4. Speed ratio calculation:

Z2
i=
η Z1
Where:
Z1, Z2 are number of starts in worm and no of teeth in gear respectively.
Number of starts on worm is to be selected according to Table 1.

Table 1
i <5 5 - 10 10 - 15 15 - 30 >30
Z1 6 4 3 2 1

η is the efficiency of power transmission, as given in Table 2.

Table 2
Z1 4 3 2 1
 η 0.9 0.85 0.8 0.7
5. Select suitable module from Table 3

Table 3
module 1 1.25 1.6 2 2.5 3.15 4 5 6.3 8 10 12.5 16 20

6. Adjust the wheel diameter

d 2 =mZ 2

7. Readjust the worm pitch diameter according to Eq. 3

The circular pitch of the gear has to be equal to the axial pitch of the worm

PCircular = PAxial
π m=PAxial
PAxial =π mZ1
8. Calculate the length of the worm

L = (11 – 12) m (Worm cutting portion length)

Di = d1 – 2 * 1.25 * m
Do = d1 + 2 m

9. Calculate the wheel face width

F » 0.75d1
Zm
tan b = 1 (Lead angle ≈ 15o – 25o)
d1

10. Forces on the worm

2T1
Ft1 =
d1
F
Fa1 = t1
tan b

Ft1 tan a n
Fr1 =
sin b

11. Self locking condition

m ³ tan b
12. Most common materials

Worm materials:
• Steel 60
• Steel 70
• Alloy Steel

Gear material:
• Bronze (e.g. Gz Cu Sn 12 with sc = 480 MPa DIN 17662)

13. Critical part in the system is the Wheel

14. Symbols used

All dimensions are in mm

a center distance between the wheel and the worm

d1 diameter of the worm
d2 diameter of the wheel
T1 torque on the worm [N.m]
T2 torque on the wheel [N.m]
i speed ratio
Z1 number of starts of the worm
Z2 number of teeth of the wheel
m coefficient of friction

b lead angle

sc contact stress in wheel [MPa]

h efficiency of power transmission

L length of cut portion
Di inner diameter of worm
Do outer diameter of worm
m worm module
 CALCULATION OF SAFETY FACTOR FOR WORM GEARS
After choosing suitable worm gear set dimensions, we have to check the safety factor
against both contact failure and bending breakage as following:

1. Factor of safety against contact failure(surface contact fatigue) SH

s H lim * Z h * Z N
SH = ³ SHlim
K
Z E * Z P * 1000* T2 * 3A
a
Where:

T2 Applied torque on wheel in Nm

σ H lim Wheel contact strength in N/mm2 from Table A-1
ZE Elasticity factor in N/mm2 from Table A-1
Zh Life Factor depends on reducer life in working hours, according to Fig. A-1
ZN Speed factor depends on wheel rpm (n2), according to Fig. A-2
ZP Contact factor, according to Fig. A-3
KA Service factor depends on driving and driven machines and working
conditions, ranges from 1 to 2.5
a Center distance in mm
SH lim Minimum safety factor against contact failure, ranges from 1 to 1.3

2. Factor of safety against tooth bending breakage SF

U lim * m * b2
SF = ³ SF lim
Ft 2 * K A
Where:
U lim Wheel bending fatigue strength in N/mm2 from Table A-1
m Module in mm
b2 Wheel face width in mm, according to eq. A-3a,b
Ft2 Wheel Tangential force in N
KA Service factor depends on driving and driven machines and working
conditions, ranges from 1 to 2.5
SF lim Minimum safety factor against tooth breakage ≥ 1

b 2 » 0.45*(d1 + 4* m) for C.I. and Bronze Wheels

b 2 » 0.45*(d1 + 4* m) + 1.8* m for light alloy wheels

Table A-1. Material properties for common gear material
Gear Surfac
M i l
 Fig. A.1 Life Factor Zh
Life factor Zh

Life in Hours

Fig. A.2 Speed Factor ZN Fig. A.3 Contact Factor ZP

Velocity Factor ZN

Contact Factor ZP

Worm dia./ center distance

Worm wheel speed (n2) in rpm ( d1/a)