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Worm Gears

Introduction..... Nomenclature..... Design Parameters..... Specifications..... Worm Gear Profiles.....

Materials..... Design Process.....
Thermal Design..... Worm Gear Formulue..... Friction Factors..... 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.
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

αn = Normal pressure angle = 20o as standard

γ = Worm lead angle = (180 /π ) tan-1 (z 1 / q)(deg)   ..Note: for α n= 20o  γ should be less than
25o
b a = Effective face width of worm wheel. About 2.m √ (q +1) (mm)
b l = Length of worm wheel. About 14.m. (mm)
c = clearance   c min = 0,2.m cos γ ,  c max = 0,25.m cos γ (mm)
d 1 = Ref dia of worm (Pitch dia of worm (m)) = q.m (mm)
d a.1 = Tip diameter of worm = d 1 + 2.h a.1 (mm)
d 2 = Ref dia of worm wheel (Pitch dia of wormwheel) =( p x.z/π ) = 2.a - d 1 (mm)
d a.2 = Tip dia worm wheel (mm)
h a.1 = Worm Thread addendum = m (mm)
h f.1 = Worm Thread dedendum , min = m.(2,2 cos γ - 1 ) , max = m.(2,25 cos γ - 1 )(mm)
m = Axial module = p x /π (mm)
m n = Normal module = m cos γ(mm)
M 1 = Worm torque (Nm)
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 = diameter factor 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
q = Worm diameter factor = d 1 / m - (Allows module to be applied to worm )
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 gear design parameters

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
is designed disperse heat to the surroundings and lubrication is and 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.
Specifications
BS721 Pt2 1983 Specification for worm gearing — Metric units.
This standard is current (2004) and provides information on tooth form, dimensions of
gearing, tolerances for four classes of gears according to function and accuracy, calculation
of load capacity and information to be given on drawings.

Worm teeth Profile

The sketch below shows the normal (not axial) worm tooth profile as indicated in BS 721-2
for unit module (m = 1mm) other module teeth are in proportion e.g. 2mm module teeth are
2 times larger

Materials used for gears

Material Notes applications

Worm
Toys, domestic appliances,
Acetal / Nylon Low Cost, low duty
instruments
Excellent machinability, Used infrequently in modern
Cast Iron
medium friction. machinery
Low cost, reasonable Power gears with medium
Carbon Steel
strength rating.
Hardened High strength, good Power gears with high rating
Steel durability for extended life
Wormwheel

Acetal /Nylon Low Cost, low duty
Reasonable strength, low
Phos Bronze friction and good
compatibility with steel
Excellent machinability,
Cast Iron
medium friction.
Toys, domestic appliances,
instruments
Normal material for worm
gears with reasonable
efficiency
Used infrequently in modern
machinery

Design of a Worm Gear

The following notes relate to the principles in BS 721-2
Method associated with AGMA are shown below..

Initial sizing of worm gear.. (Mechanical)

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
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
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

6) Complete design of gearbox including design of shafts, lubrication, and casing ensuring
sufficient heat transfer area to remove waste heat.

Initial sizing of worm gear.. (Thermal)

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

The reduction ratio of a worm gear ( R g )

Rg=z2/z1

eg a 30 tooth wheel meshing with a 2 start worm has a reduction of 15

Tangential force on worm ( F wt )= axial force on wormwheel

F wt = F ga = 2.M 1 / d 1

Axial force on worm ( F wa ) = Tangential force on gear

F wa = F gt = F wt.[ (cos α n - μ tan γ ) / (cos α n . tan γ + μ ) ]

Output torque ( M 2 ) = Tangential force on wormwheel * Wormwheel reference diameter /2

M 2 = F gt* d 2 / 2

Relationship between the Worm Tangential Force F wt and the Gear Tangential force F gt

F wt = F gt.[ (cos α n . tan γ + μ ) / (cos α n - μ tan γ ) ]

Relationship between the output torque M 2and the input torque M 1

M 2 = ( M 1. d 2 / d 1 ).[ (cos α n - μ tan γ ) / (cos α n . tan γ + μ ) ]

Separating Force on worm-gearwheel ( F s )

F s = F wt.[ (sin α n ) / (cos α n . sin γ + μ .cos γ ) ]

Efficiency of Worm Gear (η )

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

η = [(cos α n - μ tan γ ) / (cos α n . tan γ + μ ) ] / cot γ

= [(cos α n - μ .tan γ ) / (cos α n + μ .cot γ )]

Sliding velocity ( V s )...(m/s)

V s (m/s ) = 0,00005236. d 1. n 1 sec γ

= 0,00005235.m.n (z 12 + q 2 ) 1/2

Peripheral velocity of wormwheel ( V p) (m/s)

V p = 0,00005236,d 2. n 2

Friction Coefficient

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

Sliding Friction Sliding Friction

Speed Coefficient Speed Coefficient
m/s μ m/s μ
       
0 0,145 1,5 0,038
0,001 0,12 2 0,033
0,01 0,11 5 0,023
 0,05 0,09 8 0,02
0,1 0,08 10 0,018
0,2 0,07 15 0,017
0,5 0,055 20 0,016
1 0,044 30 0,016

Worm Design /Gear Wear / Strength Equations to BS721

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..

Permissible Load for Strength

The permissible torque (M in Nm) on the gear teeth is obtained by use of the equation

M b = 0,0018 X b.2σ bm.2. m. l f.2. d 2.

( example 87,1 Nm = 0,0018 x 0,48 x 63 x 20 x 80 )

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

Permissible Torque for Wear

The permissible torque (M in Nm) on the gear teeth is obtained by use of the equation

M c = 0,00191 X c.2σ cm.2.Z. d 21,8. m

( example 33,42 Nm = 0,00191 x 0,3234 x 6,7 x 1,5157 x 801,8 x 2 )

X c.2 = Speed factor for wear ( Worm wheel )

σ cm.2 = Surface stress factor for Worm wheel
Z = Zone factor.

Length of root of worm wheel tooth

Radius of the root = R r= (d 1 /2 + h ha,1 (= m) + c(= 0,25.m.cos γ )
R r= d 1 /2 + m(1 +0,25 cosγ)
l f.2 = 2.R r.sin-1 (2.R r / b a)
Note: angle from sin-1(function) is in radians...

Speed Factor for Bending

This is a metric conversion from an imperial formula..
X b.2 = speed factor for bending = 0,521(V) -0,2

V= Pitch circle velocity =0,00005236*d 2.n 2 (m/s)

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.

Table of speed factors for bending

RPM (n2) X b.2 RPM (n2) X b.2

1 0,62 600 0,3
10 0,56 1000 0,27
20 0,52 2000 0,23
60 0,44 4000 0,18
100 0,42 6000 0,16
200 0,37 8000 0,14
400 0,33 10000 0,13

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

Factors used in equations 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 μ m
else use less than 1

Tooth contact factor (K C

This relates to the quality and rigidity of gears . Use 1 for first estimate
K C = 1 For grade A gears with > 40% height and > 50% width contact
= 1,3 - 1,4 For grade A gears with > 30% height and > 35% width contact
= 1,5-1,7 For grade A gears with > 20% height and > 20% width contact

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

Time / Duty factor (K H) ..

K H for 27000 hours life (10 years) with uniform driver and driven loads
For other conditions see table below

Tables for use with BS 721 equations

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

Table of Worm Gear Speed Factors

Note -sliding speed = Vs and Rotating speed = n2 (Wormwheel)

Sliding Rotating
KV KR
speed Speed
m/s   rpm  
0 1 0,5 0,98
0,1 0,75 1 0,96
0,2 0,68 2 0,92
0,5 0,6 10 0,8
1 0,55 20 0,73
2 0,5 50 0,63
5 0,42 100 0,55
10 0,34 200 0,46
20 0,24 500 0,35
30 0,16 600 0,33
Stress Factors

Table of Worm Gear Stress Factors

C.Steel   
Other 0,4% 0,55%
  metal P.B.     C.I.     C.Stee C.Stee
Case.
(Worm) l l
H'd
Bendin
g
Metal (σbm ) Wear ( σ cm )
(Wormwheel)

MPa MPa
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 Chille
d
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
138 10,7 6,9      
steel
0,55% Carbon
173 15,2 8,3      
steel
Carbon Steel
276 48,3 30,3     15,2
(Case hardened)

Zone Factor (Z)

If b a < 2,3 (q +1)1/2 Then Z = (Basic Zone factor ) . b a /2 (q +1)1/2
If b a > 2,3 (q +1)1/2 Then Z = (Basic Zone factor ) .1,15

Table of Basic Zone Factors

 
q
z
6 6,5 7 7,5 8 8,5 9 9,5 10 11 12 13 14 17 20
1
1 1,0 1,0 1,0 1,0 1,0 1,1 1,1 1,1 1,1 1,1 1,20 1,2 1,3 1,4 1,50
 45 48 52 65 84 07 28 37 43 6 2 6 18 02 8
0,9 1,0 1,0 1,0 1,1 1,1 1,2 1,2 1,2 1,2 1,3 1,3 1,4 1,57
2 1,28
91 28 55 99 44 83 14 23 31 5 2 6 47 5
0,8 0,8 0,9 1,1 1,2 1,2 1,3 1,3 1,3 1,3 1,39 1,4 1,4 1,5 1,67
3
22 9 89 09 09 6 05 33 5 65 3 22 42 32 4
0,8 0,8 0,9 1,0 1,2 1,7 1,3 1,4 1,4 1,4 1,51 1,5 1,5 1,6 1,79
4
26 3 81 98 04 01 8 28 6 9 5 45 7 66 8
0,9 0,9 1,0 1,1 1,2 1,3 1,4 1,4 1,5 1,6 1,63 1,6 1,6 1,7 1,88
5
47 91 5 22 16 15 17 9 5 1 2* 52 75 65 6
1,1 1,1 1,1 1,2 1,2 1,3 1,4 1,5 1,5 1,6 1,69 1,7 1,7 1,8 1,92
6
31 45 72 2 87 5 38 21 88 25 4 14 33 18 8
1,3 1,3 1,3 1,4 1,4 1,5 1,6 1,7 1,72 1,7 1,7 1,8
7    1,98
16 4 7 05 52 4 14 04 5 4 6 46
1,4 1,4 1,5 1,6 1,7 1,73 1,7 1,7 1,8
8        1,5 1,96
37 62 57 23 15 8 53 78 68
157 1,6 1,6 1,7 1,74 1,7 1,7 1,8
9            1,97
3 04 48 2 3 67 9 8
1 1,6 1,7 1,74 1,7 1,7 1,8
                1,98
0 8 28 8 73 98 88
1 1,7 1,75 1,7 1,8 1,8 1,98
                 
1 32 3 77 02 92 7
1 1,7 1,8 1,8 1,99
                    1,76
2 8 06 95 2
1 1,7 1,8 1,8 1,99
                     
3 84 06 98 8
1 1,8
                        1,9 2
4 11

Duty Factor

Duty - time Factor K H

KH
Impact from Expected life Impact From Load
Prime mover hours Medium
Uniform Load Strong impact
Impact
1500 0,8 0,9 1
Uniform Load
Motor Turbine 5000 0,9 1 1,25
Hydraulic 27000 1 1,25 1,5
motor
60000 1,25 1,5 1,75
Light impact 1500 0,9 1 1,25
multi-cylinder 5000 1 1,25 1,5
 27000 1,25 1,5 1,75
engine 60000 1,5 1,75 2
Medium 1500 1 1,25 1,5
Impact 5000 1,25 1,5 1,75
Single
cylinder 27000 1,5 1,75 2
engine 60000 1,75 2 2,25

Worm q value selection

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 for optimum q value selection

Number of Teeth On Worm Gear (z 2)

q 20 25 30 35 40 45 50 55 60 65 70 75 80
6 150 250 380 520 700                
6.5 100 150 250 350 480 660              
7 70 110 170 250 350 470 620 700          
7.5 50 80 120 180 240 330 420 550 670        
8 25 50 80 120 180 230 300 380 470 570 700    
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

AGMA method of Designing Worm Gears

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)

( C 0,875 / 3 )   ≤  d 1    ≤   ( C 0,875 / 1,6 )

Metric ( mm)

( C 0,875 / 2 )   ≤  d 1   ≤   ( C 0,875 / 1,07 )

The acceptable tangential load (W t) all

(W t) all = C s. d 20,8 .b a .C m .C v . (0,0132) (N)

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

Modified Lewis equation for stress induced in worm gear teeth

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

The friction force = W f

W f = f.W t / (. cos φ n ) (N)

γ = worm lead angle at mean diameter

α n = normal pressure angle

The sliding velocity = V s

V s = π .n 1. d 1 / (60,000 )

d 1 = mean dia of worm (mm)

n 1 = rotational speed of worm (revs/min)
The torque generated γ at the worm gear = M b (Nm)

T G = W t .d 1 / 2000

The required friction heat loss from the worm gearbox

H loss = P in ( 1 - η )

η = gear efficiency as above.

C s values

C s = 270 + 0,0063(C )3... for C ≤ 76mm ....Else

C s (Sand cast gears ) = 1000 for d 1 ≤ 64 mm ...else... 1860 - 477 log (d 1 )

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

NG = Number of teeth on worm gear.

NW = Number of stards on worm gear.
mG = gear ration = NG /NW

C v values

C v (V s > 3,56 m/s ) = 0,659 exp (-0,2167 V s )

C v (3,56 m/s ≤ V s < 15,24 m/s ) = 0,652 (V s) -0,571 )

C v (V s > 15,24 m/s ) = 1,098.( V s ) -0,774 )

f values

f (V s = 0) = 0,15

f (0 < V s ≤ 0,06 m/s ) = 0,124 exp (-2,234 ( V s ) 0,645

f (V s > 0,06 m/s ) = 0,103 exp (-1,1855 ( V s ) ) 0,450 ) +0,012