Chapter 4 : Worm Gears

Section 4.9

Example 4.5 :
A worm transmitting 2.2 kW power at 1000 r.p.m. drives a worm gear rotating at 20 r.p.m.
The pitch diameter of the right hand, single start worm is 60 mm. The transverse pitch of the
o
worm gear is 15.7 mm, while the normal pressure angle is 14.5 . The worm is above the worm
gear and rotates in clockwise direction as viewed from the right side. Determine:
(i) the components of tooth force acting on the worm and worm gear;
(ii) the efficiency of worm gear pair;
(iii) the power lost in friction;
(iv) whether or not the drive is self-locking; and
(v) the designation of worm gear pair.
Use the following relation for coefficient of friction:
0.0765
 =
Vs + 0.4
where, Vs = sliding velocity, m/s.
Solution :
Given : Pi = 2200 W ; nw = 1000 r.p.m. ;
ng = 20 r.p.m. ; dw = 60 mm ;
zw = 1 ; pt = 15.7 mm ;
o 0.0765
n = 14.5 ;  = .
Vs + 0.4
pt = m
15.7 = m
m = 5 mm
dw 60
q = m = 5 = 12
zw
tan  = q

– 1 ⎡ zw ⎤ 1
= tan ⎡ 12⎤ = 4.76
–1 o
  = tan
⎣ q ⎦ ⎣ ⎦
nw zg
G = n = z
g w

1000 zg
 20 = 1
 zg = 50
 Machine Design - II (GTU) 4-2 Worm Gears

dg = m  zg = 5  50 = 250 mm
dw nw   60  20
Vw = = = 3.141 m/s
60  1000 60  1000
dg ng   250  20
Vg = = = 0.262 m/s
60  1000 60  1000
Vs = V w + Vg =
2 2
(3.141) + (0.262) = 3.152 m/s
2 2

0.0765 0.0765
 = = = 0.0406
Vs + 0.4 3.152 + 0.4
 ⎤ ⎡ 0.0406 ⎤ = 2.401o
[ v ] = tan ⎡⎢
–1 –1 1
v = tan
n ⎥⎦
= tan
⎣ cos ⎣ cos (14.5) ⎦
(i) Components of tooth force acting on worm and worm gear :
The tangential force acting on worm is given by,
Pi 2200
( Fw )t = V = 3.141 = 700.41 N
w

The axial force acting on worm is given by,

( Fw) t 700.41
( Fw ) a = = tan (2.401 + 4.76) = 5574.83 N
tan ( v + )
The radial force acting on worm is given by,
tan n ⎡ tan  ⎤
( Fw ) r = ( Fw) t 
sin  ⎣ tan v + tan  ⎥⎦
⎢
tan (14.5) tan (4.76)
= 700.41  sin (4.76) ⎡ tan (2.401) + tan (4.76) ⎤
⎣ ⎦
or ( Fw ) r = 1451.81 N
The components of force acting on the worm gear are :
( Fg )t = ( Fw )a = 5574.83 N
( Fg )a = ( Fw )t = 700.41 N
( Fg )r = ( Fw )r = 1451.81 N
( Fw )t = 700.41 N
( Fw )a = 5574.83 N
( Fw )r = 1451.81 N
( Fg )t = 5574.83 N
( Fg )a = 700.41 N
( Fg )r = 1451.81 N ...Ans.
 Machine Design - II (GTU) 4-3 Worm Gears

Fig. 4.5.1 shows the components of force acting on worm and worm gear.

Fig. 4.5.1

(ii) Efficiency of worm gear pair :

tan  tan (4.76)
 = = tan (2.401 + 4.76)
tan ( v + )
= 0.6627 or 66.27 %
or  = 0.6627 or 66.27% ...Ans.

(iii) Power lost in friction :

Pf = (1 – ) Pi
= (1 – 0.6627)  2.2
or Pf = 0.742 kW ...Ans.
(iv) Whether or not the drive is self-locking :
As  = 0.6627 > 0.5, the drive is not self-locking.
(v) Designation of worm gear pair :
The designation of gear pair is zw / zg / q / m i.e. 1/50/12/5.
 Machine Design - II (GTU) 4-4 Worm Gears

Example 4.6 :
A worm transmits 3kW power at 1440 r.p.m. and drives a gear having 60 teeth. The pitch
circle diameter of worm is 90 mm and is triple threaded. The module of worm gear is 4 mm.
The worm is right handed and rotates in clockwise direction when seen from left. Assuming
worm is above the worm wheel, calculate :
(1) the components of tooth force ; and
(2) the efficiency of drive
Also, sketch the arrangement showing the components of tooth force.
Solution :
Given : zw = 3 ; nw = 1440 r.p.m. ;
Pi = 3000 W ; zg = 60 ;
dw = 90 mm ; m = 4 mm.
dw 90
q = m = 4 = 22.5
zw
tan  = q

– 1 ⎡ zw ⎤ –1 ⎡ 3 ⎤
  = tan = tan = 7.6o
⎣ q ⎦ ⎣ 22.5 ⎦
Assume n = 20 and  = 0.1

v = tan
–1
v = tan
–1 ⎡  ⎤ = tan – 1 ⎡ 0.1 ⎤ = 6.074o
⎢ cos  ⎥ ⎣ cos 20 ⎦
⎣ n⎦
 dw nw   90  1440
Vw = = = 6.786 m/s
60  1000 60  1000
(i) Components of tooth force acting on worm and worm gear :
The tangential force acting on worm is given by,
Pi 3000
( Fw )t = V = 6.786 = 442.1 N
w

The axial force acting on worm is given by,

( Fw )t 442.1
( Fw )a = = = 1817.15 N
tan ( v +  ) tan ( 6.074 + 7.6 )
The radial force acting on worm is given by,
tan n ⎡ tan  ⎤
( Fw )r = ( Fw )t 
sin  ⎢⎣ tan v + tan  ⎥⎦
tan (20) tan (7.6)
= 442.1  sin (7.6) ⎡ tan (6.074) + tan (7.6) ⎤
⎣ ⎦
or (Fw )r = 676.86 N
 Machine Design - II (GTU) 4-5 Worm Gears

The components of force acting on worm gear are :

( Fg )t = ( Fw )a = 1817.15 N
( Fg )a = ( Fw )t = 442.1 N
( Fg )r = ( Fw )r = 676.86 N
( Fw )t = 442.1 N
( Fw )a = 1817.15 N
( Fw )r = 676.86 N
( Fg )t = 1817.15 N
( Fg )a = 442.1 N
( Fg )r = 676.86 N ...Ans.
Fig. 4.6.1 shows the components of force acting on worm and worm gear.

Fig. 4.6.1
(ii) Efficiency of worm gear pair :
tan  tan (7.6)
 = = = 0.5484
tan ( v + ) tan (6.074 + 7.6)
 = 0.5484 or 54.84% ...Ans.
Example 4.8 :
A 2/40/10/5 worm gear pair is driven by 5 kW, 720 r.p.m electric motor. The worm has right
o
hand threads and pressure angle is 20 . The worm is above the worm gear and rotates in
anticlockwise direction as viewed from the left side. The worm gear is mounted centrally
between two bearings which are 120 mm apart. If the right side bearing takes the complete
thrust load, determine :
 Machine Design - II (GTU) 4-6 Worm Gears

(i) the components of tooth force acting on the worm and worm gear;
(ii) the efficiency of worm gear pair; and
(iii) the reactions at two bearings.
Table 4.8.1 gives the coefficient of friction.
Table 4.8.1

Sliding Velocity, Vs ( m/s) 1 1.5 2.0 2.5

Coefficient of Friction,  0.0451 0.0385 0.0344 0.0313
Solution :
Given : zw = 2 ; zg = 40 ;
q = 10 ; m = 5;
Pi = 5000 W ; nw = 720 r.p.m ;
o
n = 20 .
dw = m  q = 5  10 = 50 mm
zw
tan  = q

– 1 ⎡ zw ⎤ 2
= tan ⎡ 10 ⎤ = 11.31
–1 o
  = tan
⎣ q ⎦ ⎣ ⎦
 dw nw   50  720
Vw = = = 1.885 m/s
60  1000 60  1000
Vw 1.885
Vs = = cos (11.31) = 1.922 m/s
cos 
From Table 4.8.1 for Vs = 1.922 m/s, the coefficient of friction ‘’ can be obtained by
linear inerpopolation.
0.0385 – 0.0344
 = 0.0344 + 2.0 – 1.5 (2.0 – 1.922)

= 0.0350

v = tan
–1
[ v ] = tan
–1 ⎡  ⎤ = tan – 1⎡ 0.0350 ⎤ = 2.133o
⎢ cos  ⎥ ⎣ cos (20) ⎦
⎣ n⎦

(i) Components of tooth force acting on worm and worm gear :

The tangential force acting on worm is given by,
Pi 5000
( Fw)t = V = 1.885 = 2652.52 N
w

The axial force acting on worm is given by,

( Fw)t 2652.52
( Fw)a = = = 11097.16 N
tan ( v + ) tan (2.133 + 11.31)
 Machine Design - II (GTU) 4-7 Worm Gears

The radial force acting on worm is given by,

tan n ⎡ tan  ⎤
( Fw)r = ( Fw)t 
sin  ⎢⎣ tan v + tan  ⎥⎦
tan (20) tan (11.31)
= 2652.52  sin (11.31) ⎡ tan (2.133) + tan (11.31) ⎤
⎣ ⎦
or ( Fw)r = 4149.95 N
The components of force acting on worm gear are :
( Fg)t = ( Fw)a = 11097.16 N
( Fg)a = ( Fw)t = 2652.52 N
( Fg)r = ( Fw)r = 4149.95 N
( Fw)t = 2652.52 N
( Fw)a = 11097.16 N
( Fw)r = 4149.95 N
( Fg)t = 11097.16 N
( Fg)a = 2652.52 N
( Fg)r = 4149.95 N ...Ans.
Fig. 4.8.1 shows the components of force acting on worm and worm gear.

Fig. 4.8.1
(ii) Efficiency of Worm Gear Pair :
tan  tan 11.31
 = =
tan (v + ) tan (2.133 + 11.31)
 Machine Design - II (GTU) 4-8 Worm Gears

= 0.8367 or 83.67%
 = 0.8367 or 83.67% ...Ans.
(iii) Bearing reactions :
 The bearing reactions on the worm gear shaft can be determined according to the
procedure explained in Section 3.15 (Chapter 3).
 The forces acting on the worm gear shaft are shown in Fig. 4.8.2.
 The force on the worm gear and the bearing reactions can be represented in the vector
form as follows :

F = (Fg)a  i + (Fg)t  j – ( Fg)r  k

or F = 2652.52 i + 11097.16 j – 4149.95 k ...(a)

RA = ( 0 )  i – RAy  j – RAz  k ...(b)

and RB = – RBx  i – RBy  j + RBz  k ...(c)

Fig. 4.8.2

 The position of points ‘P’ and ‘B’ can be represented in the vector form as follows :

rp = L1  i + (0)  j + rg  k

or rp = 60 i + (0)  j + 100 k ...(d)

and rB = (L1 + L2)  i + (0)  j + (0)  k

or rB = 120 i + (0)  j + (0)  k ...(e)
 Machine Design - II (GTU) 4-9 Worm Gears

 Taking moments about point A and equating to zero,

   
rp  F + rB  RB + (T) i = 0 ...(f)

⎪ i j ⎪ k
 
Now, rp  F = ⎪ 60 0 ⎪ 100
⎪ ⎪
⎪ 2652.52 11097.16 – 4149.95 ⎪
= (0 – 11097.16  100) i – (60  4149.95 – 2652.52  100) j + (60  11097.16 – 0) k
 
or rP  F = – 1109716 i + 514249 j + 665829.6 k ...(g)
i j k
  ⎪ 120 ⎪
rB  RB = ⎪ 0 0 ⎪
⎪ –R Bx – RBy RBz ⎪
 
or rB  RB = (0) i – 120 RBz j – 120 RBy  k ...(h)
Substituting Equations (g) and (h) in Equation (f), we get,
– 1109716 i + 514249 j + 665829.6 k + (0) i – 120 RBz j – 120 RBy k + (T) i = 0
( T – 1109716 ) i + ( 514249 – 120 RBz ) j + ( 665829.6 – 120 RBy ) k = 0 ...(i)
Therefore, from Equation (i),
T – 1109716 = 0
514249 – 120 RBz = 0 ...(j)
and 665829.6 – 120 RBy = 0
Solving Equation (j), we get,
T = 1109716 N-mm
RBz = 4285.41 N
RBy = 5548.58 N
Considering equilibrium of forces acting on worm gear shaft,
  
F + RA + RB = 0 ...(k)
Substituting Equations (a), (b), and (c) in Equation (k), we get,
2652.52 i + 11097.16 j – 4149.95 k + (0) i – RAy  j – RAz  k – RBx  i – RBy  j + RBz  k = 0
( 2652.52 – RBx ) i + ( 11097.16 – RAy – RBy ) j + ( RBz – RAz – 4149.95 ) k = 0
( 2652.52 – RBx ) i + ( 11097.16 – RAy – 5548.58 ) j + ( 4285.41 – RAz – 4149.95 ) k = 0 ...(l)
Therefore from Equation (l),
2652.52 – RBx = 0 ..(m)
11097.16 – RAy – 5548.58 = 0
and 4285.41 – RAz – 4149.95 = 0
 Machine Design - II (GTU) 4-10 Worm Gears

Solving Equation (m), we get,

RBx = 2652.52 N
RAy = 5548.58 N
RAz = 135.46 N
RAy = 5548.58 N
RAz = 135.46 N
RBx = 2652.52 N
RBy = 5548.58 N
RBz = 4285.41 ...Ans.
Section 4.17
Example 4.13 :
 The following data is given for a worm gear pair :
 Pitch circle diameter of worm = 48 mm
 Pitch circle diameter of worm gear = 192 mm
 Axial pitch of worm = 18.85 mm
o
 Pressure angle in axial plane of worm = 20.14
 Lead of worm = 18.85 mm
 Effective width of worm gear teeth = 36 mm
 Worm speed = 3500 r.p.m
2
 Permissible bending stress for worm gear = 90 N / mm
2
 Worm gear wear factor = 830 kN /m
 Coefficient of friction between worm and
 worm gear teeth = 0.025
2o
 Overall heat transfer coefficient without fan = 16 W / m C
–3 2o
 Overall heat transfer coefficient with fan = 15.2 + 8.25  10 nw, W / m C
–5 1.88 2
 Effective area of housing = 9  10  (a) , m
 Frictional losses in bearings = 4.5% of total input power
where, nw = worm speed r.p.m.
a = centre distance, mm
Determine :
(i) the dimensions of worm gear pair;
(ii) the input power rating on the basis of strength; and
(iii) the temperature rise of lubricating oil with fan.
Is fan necessary? Comment.
Use the following data :
2.87
Y = 0.484 – z
 Machine Design - II (GTU) 4-11 Worm Gears

⎡ zg ⎤
Lw = m ⎢4.5 + 50⎥ , mm
⎣ ⎦
ha = 1m; hf = 1.2m
Solution :
Given: dw = 48 mm ; dg = 192 mm;
o
pa = 18.85 mm ; a = t = 20.14 ;
L = 18.85 mm ; b = 36 mm;
2
nw = 3500 r.p.m ; bg = 90 N /mm ;
2
K = 0.83 N /mm ;  = 0.025.
 Dimensions of worm gear pair :
L = pa  zw
18.85 = 18.85  zw
 zw = 1
Now,
pa =  m
18.85 =  m
 m = 6 mm
dw = m  q
48 6q
=
 q =
8
dg m  zg
=
192 6  zg
=
 zg =
32
zg 32
G = z = 1 = 32
w

nw
again, G = n
g

3500
32 = ng
 ng = 109.375 r.p.m
zw
tan  = q

– 1 ⎡ zw ⎤ –1 1
= tan ⎡8 ⎤ = 7.125
o
  = tan
⎣ q ⎦ ⎣ ⎦
tan n
tan t =
cos 
 Machine Design - II (GTU) 4-12 Worm Gears

tan n = tan t  cos  = tan (20.14)  cos (7.125) = 0.3639

–1 o
 n = tan (0.3639) = 20
Hence, the dimensions of worm and worm gear :
m = 6 mm ;
zw = 1 ;
zg = 32 ;
dw = 48 mm ;
dg = 192 mm ;
pa = 18.85 mm ;
L = 18.85 mm ;
o
 = 7.125 ;
o
n = 20 ;
b = 36 mm ;
⎡ zg ⎤ 32
Lw =  m ⎢4.5 + 50 ⎥ =   6  ⎡4.5 + 50 ⎤ = 96.88 mm ;
⎣ ⎦ ⎣ ⎦
ha = 1 m = 6 mm ;
hf = 1.2 m = 1.2  6 = 7.2 mm ;
dw + dg 48 + 192
a = 2 = 2 = 120 mm. ...Ans.

 Beam strength of worm gear tooth :

2.87 2.87
Y = 0.484 – z = 0.484 – 32 = 0.3943
g

Fb = bg  b  m  Y  cos 
= 90  36  6  0.3643  cos (7.125)
or Fb = 7606.24 N ...(a)
 Wear strength of worm gear tooth :
Fw = dg  b  K = 192  36  0.83
or Fw = 5736.96 N ...(b)
 Effective load on worm gear tooth :
 d g ng   192  109.375
Vg = = = 1.09956 m/s
60  1000 60  1000
6 6
Kv = 6 + V = 6 + 1.09956 = 0.8451
g

Ka  ( Fg ) t 1  ( Fg ) t
Feff = Kv = 0.8451

or Feff = 1.1832 ( Fg )t ...(c)

 Machine Design - II (GTU) 4-13 Worm Gears

 Maximum static load worm gear tooth can take :

As Fw < Fb, gear pair is weaker in pitting, and hence pitting is the design criterion.
 Fw = Nf  Feff
Fw = Nf  1.1832 ( Fg ) t
5736.96 = 1  1.1832  ( Fg ) t
 ( Fg )t = 4848.68 N ...(d)
 Input power rating on the basis of strength :
Output power rating is given by,
Po = ( Fg ) t  Vg = 4848.68  1.09956 = 5331.41 W
or Po = 5.331 kW ...(e)

v = tan
–1
v = tan
–1 ⎡  ⎤ = tan – 1 ⎡ 0.025 ⎤ = 1.524o
⎢cos  ⎥ ⎣ cos (20) ⎦
⎣ n⎦

tan  tan (7.125)

 = = = 0.8218
tan (v + ) tan (1.524 + 7.125)
Input power rating on the basis of strength is given by,
Po 5.331
Pi = = ...(f)
 0.8218
or Pi = 6.487 kW ...Ans.
 Thermal considerations :
–5 1.88 2
A = 9  10  (a) , m
–5 1.88
= 9  10  (120)
2
or A = 0.72963 m
Total power loss,
⎧ Power lost due to ⎫ ⎧ Power lost in ⎫
Pf = ⎨ ⎬ + ⎨ ⎬
friction between teeth ⎭
⎩ ⎩ bearing friction ⎭
4.5
= (1 – ) Pi + 100 Pi
4.5  6487
= (1 – 0.8218)  6487 + 100
or Pf = 1447.9 W ...(g)
 Rate of heat generation, Hg = Pf = 1447.9 W
(i) With fan :
–3 2o
C = 15.2 + 8.25  10 nw W / m C
–3
= 15.2 + 8.25  10  3500
2o
or C = 44.075 W /m C
 Machine Design - II (GTU) 4-14 Worm Gears

 Rate of heat dissipation,

Hd = CA t
= 44.075  0.72963  t, W
or Hd = 32.158 t, W
Now Hg = Hd
1447.9 = 32.158 t
o
 t = 45.02 C
o
(t)with fan = 45.02 C …Ans.
(ii) Without fan :
2o
C = 16 W/m C
 Rate of heat dissipation,
Hd = CA t
= 16  0.72963  t
or Hd = 11.674 t, W
Now Hg = Hd
1447.9 = 11.674 t
o
 t = 124.02 C
o o
(t)without fan = 124.02 C > 50 C
o
As (t)without fan > 50 C , fan is necessary for effective heat dissipation. ...Ans.
Example 4.17 :
A pair of worm and worm wheel is designated as 2/72/10/6. The worm transmits 8 kW at
2
1800 r.p.m to a worm wheel. The permissible bending strength is 110N/mn . The wear load
2
factor is 0.83 N/mn . If the coefficient of friction is 0.05 and normal pressure angle is 20,
determine :
(i) the factor of safety against bending;
(ii) the factor of safety against wear and;
(iii) the factor of safety against heat dissipation.
Use the following data :
Input power rating based on thermal consideration,
1.7
a
kW = 34.5 (i + 5)
where,
a = centre distance
i = gear ratio.
2.87
Y = 0.484 – z
 Machine Design - II (GTU) 4-15 Worm Gears

Solution :
Given : zw = 2 ; zg = 72 ;
m = 6 mm ; q = 10 ;
pi = 8000 mm ; nw = 1800 r.p.m. ;
2 2
bg = 110 N / mm ; K = 0.83 N / mm ;
o
 = 0.05 ; h = 20 .
zw 2
tan  = q = 10 = 0.2
–1 o
 = tan (0.2) = 11.31
zg 72
G = zw = 2 = 36
nw
Now, G = ng
nw 1800
 ng = G = 36 = 50 r.p.m
 Effective load on worm gear tooth :
 ⎤ 0.05
V = tan– 1 v = tan– 1 ⎡⎢ = tan ⎡ cos (20) ⎤ = 3.045
–1 o
⎥ ⎣ ⎦
⎣ cos n ⎦
tan  tan (11.31)
 = = = 0.7815
tan (v + ) tan (3.045 + 11.31)
Po = Pi   = 8000  0.7815= 6252 W
 d g ng  m zg ng   6  72  50
Vg = = = = 1.131 m/s
60  1000 60  1000 60  1000
Po 6252
( Fg ) t = V = 1.131 = 5527.9 N ...(a)
g
6 6
Kv = 6 + V = 6 + 1.131 = 0.8414
g

Ka  ( Fg ) t 1.0  5527.9
Feff = Kv = 0.8414

or Feff = 6596.91 N ...(b)

 Beam strength of worm gear tooth :
Assume, b = 0.73 dw = 0.73 mq = 0.73  6  10 = 43.8 mm or 44 mm
 b = 44 mm
For 20 full-depth involute tooth system,
2.87 2.87
Y = 0.484 – z = 0.484 – 72 = 0.4441
g
 Machine Design - II (GTU) 4-16 Worm Gears

Fb = bg  b  m  Y  cos 
= 110  44  6  0.4441  cos (11.31)
or Fb = 12646.21 N ...(c)
 Factor of safety against bending failure :
The factor of safety available against bending failure is given by,
Fb 12646.21
Nfb = F = 6569.91
eff

or Nfb = 1.92 ...Ans.

 Wear strength of worm gear tooth :
dg = m  zg = 6  72 = 432 mm
Fw = dg  b  K
= 432  44  0.83
or Fw = 15776.64 N ...(d)
 Factor of safety against pitting failure :
The factor of safety available against pitting failure is given by,
Fw 15776.64
Nfw = F = 6569.91
eff

or Nfw = 2.4 ...Ans.

 Thermal considerations :
dw = mq = 6  10 = 60 mm
dg = mzg = 6  72 = 432 mm
dw + dg 60 + 432
a = 2 = 2
or a = 246 mm
Input power based on heat dissipation is,
1.7 1.7
a (246)
Pih = 34.5 (G + 5) = 34.5 (36 + 5)

or Pih = 8.2 kW
Factor of safety based on heat dissipation
Pih 8.2
Nfh = P = 8.0
i

or Nfh = 1.025 …Ans.