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Design of Worm Gears

This document provides a solution to designing a worm gear drive to transmit power. It includes calculating dimensions, tooth loads, efficiency, and heat dissipation. Key parameters and equations from technical handbooks are used to solve for values like pitch diameter, centre distance, tangential load capacity, wear load, efficiency, and maximum gear temperature.

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venkatesh
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111 views

Design of Worm Gears

This document provides a solution to designing a worm gear drive to transmit power. It includes calculating dimensions, tooth loads, efficiency, and heat dissipation. Key parameters and equations from technical handbooks are used to solve for values like pitch diameter, centre distance, tangential load capacity, wear load, efficiency, and maximum gear temperature.

Uploaded by

venkatesh
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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Pg 23

Miscellaneous Problems

Pbm) Design a worm gear drive to transmit a power of 2kW at 1000 rpm. The speed ratio is 20 &
centre distance is 200 mm. Take pressure angle α = 20o FD & materials for gear – phosphor bronze
whose σd2 = 55 N/ mm2 for worm hardened steel.

Soln: Given Data

P = 2kW ; N1 = 1000 rpm ; I = 20; a = 200 mm; d = 20o FD; σd2 = 55 N/ mm2

I) Dimensions of worm & worm gear -:


𝑁 𝑍2 1000
i = 𝑁1 = 𝑍1
=> 𝑁2 = 20
= 50 𝑟𝑝𝑚
2

a0.875
Pitch Diameter of worm = d1 = 1.466 ------ 12.103/ Pg 176
a = Centre Distance in mm
2000.875
∴ 𝑑1 = = 70.35 𝑚𝑚 ≈ 70 𝑚𝑚
1.466

𝑑1 +𝑑2
Centre Distance = 𝑎 =
2

10 + 𝑑2
200 = 2
=> d2 = 330 mm  1st Estimate
According to AGMA, d1 ≈ 3Px (Px – Axial Pitch = πm)
d1 ≈ 3 x π x m
70 ≈ 3 x π x m
 m = 7.42 = 8 mm.
Pg 24

Also, we have 𝑑2 = 𝑖𝑚𝑍1


330
 𝑍1 = 20 𝑥 8
= 2.0625 = 2
 No of starts = Z1 = 2

If Z1 = 2; Z2 = iz1 = 20 x 2 = 40 teeth

From Table 12.30/page 200; we have for

m = 8 ; ΡX = 25.133 ; Z1 = 2 ; d1 = 80 mm ; q = 10;

γ = 11o19’
𝑑1 + 𝑑2
∴a= 2
80 + 𝑑2
200 = 2
=> d2 = 320 mm
𝑚𝑍1 8𝑥2
Leading edge angle = tan γ = = = 11.30𝑜
𝑑1 80

(i) Dimensions of worm [ from table 12.25 / Pg 198]


a) Z1 = 2; b) d1 = 80 mm; c) Face length of worm : Lw = (4.5 + 0.02Z1) Px (Px = πm)

= (4.5 + 0.02 x 2 ) π x 8

= 114.10 ≈ 115 mm

d) Depth of tooth = h = 0.686 x π x 8 = 17.24 mm

e) Addendum = ha = 0.318 Px = 0.318 x π x 8 = 7.99 ≈ 8 mm

f) Top Radius = r = 0.05 Px = 0.05 x π x 8 = 1.256 mm

g) Hub Diameter = dH = 1.66Px + 25 mm= 1.66 x π x 8 + 25 = 66.70 mm

h) Max bore for shaft = ds = Px + 15.9 mm= π x 8 + 15.9 = 41.03 mm

i) Outside dia of worm = d01 = d1 + 0.636 Px = 80 + 0.636 x π x 8 = 95.98 mm = 96 mm


Pg 26

(b) Tangential tooth load to be transmitted:


1000 𝑥 𝑃 𝜋𝑑2 𝑁2 𝜋 𝑥 320 𝑥 50
𝐹𝑡2 = 𝜃2
− − − −𝑤ℎ𝑒𝑟𝑒 𝑣2 = 60𝑥1000
= 60 𝑥 1000

𝑣2 = 0.837 𝑚/𝑠𝑒𝑐
1000 𝑥 2
= 0.837

= 𝐹𝑡2 = 2387.32 𝑁  tangential tooth load to be transmitted

Therefore, tangential tooth load capacity is higher than transmitted load, Design is satisfactory.

Actual power capacity / permissible power


1000 𝑥 𝑃
𝐹𝑡2 = 𝑣2

𝐹𝑡2 𝑥 𝑣2 9118.67 𝑥 0.837


𝑃= 1000
= 1000
= 7.63 𝑘𝑊

∴ 𝑃𝑒𝑟𝑚𝑖𝑠𝑠𝑖𝑏𝑙𝑒 𝑝𝑜𝑤𝑒𝑟 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 7.63 𝑘𝑊


IV) Wear Load

Dynamic Strength = 𝐹𝑑 = 𝜎𝑑 𝑏 𝑌𝑚 − −12.110/𝑃𝑔 117

𝐹𝑠 = 𝜎𝑑2 𝑏𝜋𝑦2 𝑚

= 55 𝑥 60 𝑥 𝜋 𝑥 0.1312 𝑥 8
𝐹𝑠 = 10881.47 𝑁
Wear load = 𝐹𝑁 = 𝑑2 𝑏𝐾 − − − 𝑒𝑞𝑛 12.122/ 𝑃𝑔179

From table 12.31 / page 202 for γ = 10o – 25o & phosphor bronze

K = 0.687
Pg 27

∴ 𝐹𝑊 = 320 𝑥 60 𝑥 0.687
𝐹𝑊 = 13190.4 𝑁
𝐹𝑊 > 𝐹𝑆 ; 𝑑𝑒𝑠𝑖𝑔𝑛 𝑖𝑠 𝑠𝑎𝑓𝑒
v) Efficiency
tan 𝛾 ( 1−𝜇 tan 𝛾) 12.117
𝜂= tan 𝛾+𝜇
− − − − − 𝑃𝑔 177

0.0422 12.120𝑎
𝜇 = ( 𝑉 )0.28 𝑓𝑜𝑟 0.2 < 𝑣 < 2.8 𝑚/𝑠 − − − − − 𝑃𝑔 178
𝑟

𝑣 = 0.837 𝑚/𝑠
0.837
∴ 𝑉𝑟 = 𝑉/ cos 𝛾 = cos 11.31
= 0.8535
0.0422
𝜇= (0.8535)0.28
= 0.044

𝜇 = 0.044
tan 11.30 (1−0.044 tan 11.30)
𝜂= tan 11.30+0.044

𝜂 = 0.812 = 81.2%
Pg 28

Heat Dissipation
𝜇𝐹𝑛 𝑉𝑟 12.124𝑎
Heat Generated : Q(Hg) = cos 𝑟
−−− 𝑃𝑔 179

𝐹𝑡2 9118.67
𝐹𝑛 = = = 9895.71𝑁
cos 𝛾 cos 𝛼 cos 11.30 cos 20
0.04 𝑥 9895.71 𝑥 0.8535
𝑄= = 378.96 𝐽/𝑠𝑒𝑐
cos 11.30
0.407 12.124𝑐
Heat dissipated Q(Hd) = 103
(𝐴𝑔 + 𝐴𝑤 )(𝑡2 − 𝑡1 ) − − − 𝑃𝑔 180

𝜋𝑑2 𝜋
𝐴𝑔 = = (320)2 = 80424.77 𝑚𝑚2
4 4
𝐴𝑤 = 𝐿𝑤 𝑑1 = 115 𝑥 80 9200 𝑚𝑚2
Assume t2 = Gear temp = ?

t1 = Ambient Temp = 25oC (Assume)


0.407
379 = (80424.77 + 9200)(𝑡2 − 25)
103
 t2 – 25 = 10.39
 t2 = 35.39 ≈ 36oC  Without any artificial cooling

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