Design of Worm Gears

PROF. S. K. KARMAKAR
Worm Gears :

Worm gear drives are used to transmit power between two non-
intersecting shafts, which are, in general, at right angles to each
other. The worm gear drives consists of a worm and a worm
wheel/gear. The worm is a threaded screw, while the worm wheel
is a toothed gear. The teeth on the worm wheel envelope the
threads on the worm, giving either a line or an area-contact
between mating gears. Worm gear drives are used in materials
handling equipment, m/c tools and automobiles. The advantages
of worm gear drives as follows :-

(i) The most important characteristic of worm gear drives is their

high speed reduction. A speed reduction as high as 100:1 can be
obtained with a single pair of worm gears.
 (ii) The worm gear drives are compact with small overall
dimensions, compared with equivalent spur or helical gear drives
for the same speed reduction.

(iii) The operation is smooth and silent.

(iv) Provision can be made for self-locking operation, where the

motion is transmitted only from the worm to the worm wheel. This
is advantageous in applications like crane and lifting devices.

The drawbacks of the worm gear drives are as follows :

(i) The efficiency is low compared with other types of gear

drives.

(ii) The worm wheel, in general, is made of Phosphor Bronze

which increases the cost.
 (iii) Considerable amount of heat is generated in worm gear
drives, which is required to be dissipated by a lubricating oil to the
housing walls and finally to the surroundings.

(iv) The power transmitting capacity is low. Worm gear drives are
used for upto 100 KW power transmission.

Terminology of Worm gears :-

A pair of worm gears is specified and designated by four quantities

in the following manner, z1/z2/q/m

Where z1 = number of starts on the worm

z2 = number of teeth on the worm gear

 d1
q = diametral quotient = , where d1 is the pcd of the
m
worm.
m = module (mm)
The worm is similar to a screw with multi start threads. The threads
of the worm have an involute helical profile. The axial pitch (px) of
the worm is defined as the distance between two consecutive teeth,
measured along the axis of the worm. The lead ( ) of the worm is
defined as the distance that a point on the helical profile will move
when the worm is rotated through one revolution.

Therefore,  = p x z1
As seen in the figure, the axial pitch of the worm should be equal to
the circular pitch of the worm wheel. Therefore,
d 2  (mz2 )
px = = = m
z2 z2

So  =  m z1

When one thread of the worm is developed, it becomes the

hypotenuse of a triangle.

  m z1 z1
tan  = = or tan  =
 d1  (qm) q
 1
The center distance, a = (d1 + d 2 )
2
1
= m( q + z 2 )
2

z2
When the worm wheel is rotated through one revolution, the worm will
complete z2 revolution for single start threads. For double start threads,
the number of revolutions of the worm will be z2/2,
z2 Speed of worm
So the speed ratio “i” = =
z1 Speed of worm wheel
The preferred values of z1/ z2/ q/ m for worm gearing are given in the
Table.
Preferred values of q : 8,10,12.5, 16, 20 and 25
The number of starts on the worm usually taken as 1,2 or 4.
Preferred values of z1 / z2 / q / m for worm gears.
Transmission
ratio
Centre distance (mm)
100 125 160 200 250

20 2/40/10/4 2/40/10/5 - 2/40/10/8 2/40/10/10

25 - 2/52/10/4 2/54/10/5 - 2/52/10/8

30 1/30/10/5 1/31/10/6 1/30/10/8 1/30/10/10 -

40 1/40/10/4 1/40/10/5 - 1/40/10/8 1/40/10/10

50 - 1/52/10/4 1/54/10/5 - 1/52/10/8

Proportions of worm gears :-
ha1 = addendum in mm = m
hf1= dedendum in mm = (2.2Cos − 1)m
c = 0.2 m cos  = clearance

So da1 = outside dia = d1 + 2ha1

= qm + 2m = m(q+2)
df1 = root dia = d1 – 2hf1 = qm – 2m ( 2.2 Cos −1)
= m(q + 2 − 4.4 Cos )
Dimensions of worm wheel :-

ha2 = addendum = m(2 cos  − 1)

hf2 = dedendum = m(1 + 0.2 Cos )

Outside dia = da2 = d2 + 2ha2 = m( z2 + 4Cos − 2)

Root dia = df2 = m( z2 − 2 − 0.4Cos )

The effective face width F of the worm wheel is as shown.
Tangent AB on the pitch circle is as shown.
From  AOC
(AC)2 = (AO)2 – (OC)2
2 2 2
 F  =  a1  −  1 
d d
     
2  2  2
F= 2m (q + 1)
F
From the figure Sind = 2
(d a1 + 2c) / 2
 −1F 

Or d = Sin  
 a1
d + 2 c 
The length of the root of the worm wheel teeth is arc xyz,
which is denoted by  = arc xyz
r
2d
= x  (d a1 + 2c)
2
= (d a1 + 2c)d
−1
F 

= (d a1 + 2c) Sin  
 a1
d + 2c 
Force Analysis of worm & worm gear transmission system :-
Assumptions :-
(i) Worm – Driving element & worm wheel – driven element.
(ii) The worm has right handed involute helicoid thread.
(iii)Worm rotates in clockwise directions when seen from right side.

Important : In order to decide the rotation of the worm wheel, the

worm is considered as screw and worm wheel as nut. Applying right
hand thumb rule, line motion of the screw w.r.t nut is towards left.
So w.r.t screw, the nut will move in the opposite direction i.e. to the
right. Therefore worm wheel rotates anticlockwise direction as
shown
Rotation of worm → − ve x direction
Rotation of worm wheel → + ve z direction

(P2)t = -(P1)a
(P2)a = -(P1)t
(P2)r = -(P1)r
The resultant face acting on the worm consists of two factors:
•Components of normal reaction between the meshing teeth and
components of frictional force.
•The two components are superimposed to get the resultant
components.
Components of normal reaction on worm.
fn = Normal pressure angle
 = Lead angle
Resolving normal reaction P in plane ABCD

Pn = P Cos fn

Pr = P Sin fn

Pa Resolving PN in the Plane AEBF

Pa = PN Cos  = P Cos fn Cos 

 Pt = PN Sin  = P Cos fn Sin 

Pr = P Sin fn

The frictional force is significant in worm gear drives because the

motion between the worm and the worm wheel is sliding,
compared with the rolling motion in other types of gears.
The resultant frictional force is mP where m is the coefficient of
friction. The direction of the frictional force will be along the pitch
helix and opposite to the direction of rotation. There are two
components of frictional force :
(i) Component mP Cos  is in the tangential dirn .The dirn of this
component is same as that of Pt.
 (ii (ii) Component mP Sin  is in the axial dirn. The dirn of this
component is opposite to that of Pa .

Seen from LHS

Superimposing the components of normal reaction and frictional force,

we have resultant forces
( P1)t =P Cosfn Sin + mPCos

= P(Cosfn Sin + mCos )

( P1) a =P CosfnCos − mP Sin
= P(Cosfn cos  − m Sin )
and (P1)r = P Sin fn
(CosfnCos − mSin )
Or, ( P1 ) a = ( P1 )t X
(Cosfn Sin + mCos )

Sinfn
and ( P1 ) r = ( P1 )t X
(Cosfn Sin + mCos )

NB : The direction of the three components of forces depends

upon three factors, the driving element (worm or worm wheel),
threads on the work (RH or LH) and rotation of the worm (CW
or CCW).
Friction in worm gears :-
It has been observed that the coefficient of friction in worm gear
drives depends upon the rubbing speed. The rubbing speed is the
relative velocity between the worm and the wheel. The velocity
triangle is as shown.
Where v1 = pitch line velocity of the worm (m/s)
v2 = pitch line velocity of the worm wheel (m/s)
vs = rubbing velocity (m/s)
  
vs = v1 − v2
  d1n1 v1
v1 = From velocity triangle Vs =
60(1000) cos 
 d1n1
or , vs =
60000 Cos
The variation of coefficient of friction w.r.t rubbing velocity is
shown with figure for worm wheel (Phosphor Bronze) & worm
(case hardened steel) with lubricants.
The efficiency of the worm gear drive is given by,

Power output
=
Power input
 ( P2 )t x(d 2 / 2) x n2
=
( P1 )t x (d1 / 2) x n1
n2
Where = /i
n1
n1 Speed of worm
i= =
n2 Speed of worm wheel
z2
=
z1
 z1
tan  =
q

d 2 mz2 z2 z2 / z1
= = = = i tan 
d1 mq q q / z1

( P2 )t ( P1 ) a
= tan  = tan 
( P1 )t ( P1 ) z
 (CosfnCos − m Sin  )
 = tan 
(Cosfn Sin + m Cos  )
CosfnCos − m Sin 
Cos 
=
Cosf n Sin + m Cos
Sin
Cosfn − m tan 
=
Cosfn + m Cot
Selection of materials :-
The selection of materials for the worm and the worm wheel is
more limited than it is for other types of gears. The threads of the
worm are subjected to fluctuating stresses and the number of
cycles is fairly large. Therefore, the surface endurance strength is
an important criterion in the selection of the worm material. The
core of the worm should be kept ductile and tough to ensure
maximum energy absorption. The worms are, therefore, made of
case hardened steel with a surface hardness of about 60 RC, and a
case depth of 0.75 to 4.5 mm. The magnitude of contact stresses
on the worm wheel teeth is the same as that on the worm threads.
However, the number of stress cycles are reduced by a factor
equal to the speed reduction.
The worm wheel can not be accurately generated in the hobbing
m/c. The final profile and finish of the worm wheel teeth is the
result of plastic deformation during the initial stages of service.
Therefore, the worm-wheel material should be soft and
conformable. Phosphor Bronze with a surface hardness of 90-
120 BHN is widely used for the worm wheel. Phosphor-Bronze is
costly and in case of worm wheels with large dimensions only the
outer rim is made of phosphor Bronze. It is then bottled to the
cast-iron wheel.
Strength rating of worm gears :-
Beam strength Basis :- The maximum possible torque that the
worm wheel can withstand without bending failure is given by
the lower of the following two values.
( M t )1 =17.65 X b1 Sb1 mlr d 2 cos 

( M t ) 2 =17.65 X b 2 Sb 2 mlr d 2Cos

Where (Mt)1 , (Mt)2 = Permissible torque on the worm
wheel (N – mm)
Xb1 , Xb2 = Speed factors for strength of worm and
worm wheel.
m = module (mm)
 r = Length of the root of the worm
−1 F
wheel teeth (mm) = (d a1 + 2c) Sin
d a1 + 2c
Where da1 = Outside dia of the worm = m(q+2) (mm)
c = Clearance = 0.2 m Cos  (mm)
F = effective face width = 2m q + 1 (mm)
d2 = pcd of worm wheel (mm)
 = Lead angle of the worm.
The bending stress factor Sb for various materials is given
below. The speed factor for strength (Xb) of worm gears is
obtained from the figure 20.13 (Page 620). The power
transmitting capacity based on beam strength is given by

2nM t Where Mt is the lower value between

KW =
60 X 106 (Mt)1 and (Mt)2
Sb Values (Bending Stress factors)

Material Sb

Phosphor Bronze (Centrifugally) 7.0

Phosphor Bronze(Sand cast chilled) 6.4

Phosphor Bronze (Sand cast) 5.0

0.4% Carbon Steel normalized (40 c8) 14.10

0.55% Carbon Steel normalized (55 c8) 17.6

Case hardened carbon steels (10 c4, 14 c6) 28.2

Case hardened alloy steels (16 Ni 80 Cr 60 and 20 on 2 M0 25) 33.11

Nickel Chromium Steels (13 Ni 3 Cr 80 Or 15 Ni 4 Cr 1) 35.22

Wear rating of worm gears :
The maximum permissible torque that the worm wheel can
withstand without pitting failure is given by the lower of the
following two values :
(Mt)3 = 18.64 Xc1 Sc1 Z (d2)1.8 m
(Mt)4 = 18.64 Xc2 Sc2 Z (d2)1.8 m
(Mt)3 , (Mt)4 = Permissible torque on the worm wheel (N–mm)
Xc1 , Xc2 = Speed factors for the wear of worm and worm wheel

Sc1 , Sc2 = Surface stress factors of the worm and worm

wheel
Z = Zone factor
Values of the surface stress factor
Values of Sc when running with
Materials
A B C D
A Phosphor Bronze (Centrifugally cast) - 0.85 0.92 1.55

Phosphor Bronze (Sand case & - 0.63 0.70 1.27

Chilled)
Phosphor Bronze (Sand Cast) - 0.47 0.54 1.06

B 0.4% Carbon Steel normalized (40 1.1 - - -

C8)
C 0.55% Carbon Steel normalized (55 1.55 - - -
C8)
D Case hardened carbon steel (10 C4, 4.93 - - -
14 C6)
Case hardened alloy steel (16 Ni 80 5.41 - - -
Cr 60, 20 Ni 2 M0 25)
Nickel Chromium Steel (13 Ni 3 Cr 6.19 - - -
80, 15 Ni 4 Cr 1)
Values of the Zone Factor Z

Z1 q=8 q=9 q=10 q=12 q=16 q=20

1 1.084 1.128 1.143 1.202 1.374 1.508

2 1.114 1.214 1.231 1.280 1.418 1.575

4 1.204 1.380 1.46 1.515 1.634 1.798

Thermal considerations :-
The efficiency of a worm gear drive is low and work done by
friction is converted into heat. When the worm gear operates
continuously, considerable amount of heat is generated. The rate
of heat generated is given by

H g =1000(1 −  ) x

Where Hg = rate of heat generation (w)

 = efficiency of worm gears (fraction)

x = power transmitted by gears (kW)

The heat is dissipated through the lubricating oil to the housing
wall and finally to the surrounding air. The rate of heat
dissipated (Hd) by the housing walls to the surrounding air is
given by Hd = K(tf –ta) A
Where Hd = the rate of heat dissipation (w)
K = overall heat transfer coefficient of housing walls (w/m2 oc)
tf = temperature of the lubricating oil (o c)
ta = temperature of the surrounding air (o c)
A = effective surface area of housing (m2)

Equating,
1000(1 −  ) x = K (t f − ta ) A

K (t f − t a ) A
x= ………(1)
1000(1 −  )
 1000(1 −  ) x ……….(2)
t f = ta +
KA

Equation (1) gives the power transmitting capacity based on thermal considerations.
Equation (2) gives the resultant temperature of the lubricant oil for a given power
transmitting capacity.

The overall heat transfer coefficient K under normal working conditions with natural
air circulation is 12 to 18 w/m2 o c.

The value can be further increased by providing a fan on the worm shaft and
arranging the fans horizontally along the stream of air. In such cases the value of the
overall heat transfer coefficient can be taken as 20 to 28 w/m2 oc. It has been
observed, the maxm permissible temperature for commonly used lubricating oil is
950 c, above which it loses its properties and there is a danger of gear tooth failure
due to seizure.