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DME 2 Design of Worm Gear

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DESIGN OF MACHINE ELEMENTS

Design Procedure of Worm Gear


Step 1: Material Selection
Check whether the material and its properties are given in the question or not

If given, write the material design stress here (𝝈𝒅 )

If not given choose steel as Worm material & Phosphor Bronze as Worm wheel material

Select a design stress (𝝈𝒚 ) for both Gear and Pinion from (DB Pg 234 Table 12.7)

Step 2: Identify the weaker part


Worm wheel is subjected to combined rotary and sliding action, it causes over heating of the
gear pair. So, worm wheel is expected to be weaker than worm. Therefore, design is based on
worm wheel.

Step 3: Find the centre distance & Diameters


𝐚𝟏.𝟕
P = .02905 x (DB Pg 228 Eq 12.68a)
𝐢+𝟓
Find the centre distance (a) from the above equation if not given in the question

𝐚𝟎.𝟖𝟕𝟓
Diameter of worm, 𝐝𝟏 = (DB Pg 228 Eq 12.68a)
𝟏.𝟒𝟔𝟔
Diameter of worm wheel, 𝐝𝟐
𝐝𝟏 +𝐝𝟐
using centre distance, a = (DB Pg 222 Eq 12.47a)
𝟐
Step 4: Find the Module
To Find the module of the gear, use the below equation

𝐅𝐭 = 𝛔𝐝 𝐂𝐯 𝐛 𝐘 𝐦 (DB Pg 223 Eq 12.53a)

• 𝑪𝒗 − Velocity ratio (DB Pg 223 Eq 12.53c)


𝐚𝟎.𝟖𝟕𝟓
• b=
𝟐
• Find the value of y from (DB Pg 244 Table 12.28c)
• For that find value of α from (DB Pg 243 Table 12.26)
• For that find the value of 𝐳𝟏 based on i from (DB Pg 244 Table 12.28b)
𝟏𝟎𝟎𝟎 𝐏 𝐂𝐬
• 𝐅𝐭 - 𝐯

Find the standard value of module from (DB Pg 245 Table 12.29)
Step 5: Lead Angle (𝜰)

𝐳𝟏 𝐦𝟐
𝐝𝟏 = (DB Pg 221 Eq 12.46h)
𝒕𝒂𝒏 𝜰

Step 6: Dynamic Strength


𝐅𝐬 = 𝛔𝐝 𝐛 𝐘 𝐦 (DB Pg 223 Eq 12.54)

Step 7: Wear Strength:


𝐅𝐰 = 𝐝𝟐 b K (DB Pg 227 Eq 12.62a)

Step 8: Efficiency:
𝒄𝒐𝒔𝜭−µ𝒕𝒂𝒏 𝜰
𝛈= (DB Pg 225 Eq 12.57d)
𝒄𝒐𝒔𝜭+µ𝒄𝒐𝒕 𝜰

Or
𝒕𝒂𝒏 𝜰(𝟏−µ𝒕𝒂𝒏 𝜰)
𝛈= (DB Pg 225 Eq 12.57b)
µ+ 𝒕𝒂𝒏 𝜰
𝟎.𝟎𝟒𝟐𝟐
µ= , for 0.2≤𝐯𝐫 ≤2.7 m/s (DB Pg 226 Eq 12.60a)
𝐯𝐫 𝟎.𝟐𝟖

𝟑.𝟐𝟖𝟏
µ = 0.025 + 𝐯 , for 𝐯𝐫 ≥ 𝟐. 𝟕𝟓𝟖 𝐦/𝐬 (DB Pg 226 Eq 12.60b)
𝟏𝟎𝟎𝟎 𝐫

𝚷 𝐝𝟏 𝐧𝟏
𝐯𝐫 = (DB Pg 226 Eq 12.60b)
𝟏𝟎𝟎𝟎 𝐜𝐨𝐬 𝚼

Step 9: Heat Generated:


µ 𝐅𝐧 𝐕 𝐫
𝐐𝐠 = (DB Pg 227 Eq 12.63a)
𝐜𝐨𝐬 𝚼
Find 𝐅𝐧 from (DB Pg 225 Eq 12.56k)
Step 10: Heat Dissipated:
𝐐𝐝 = 𝟏𝟎𝟎𝟎(𝐤𝐰)(𝟏 − 𝛈) (DB Pg 227 Eq 12.63b)

If change in temperature is given


𝟎.𝟒𝟎𝟕
𝐐𝐝 = (𝐀𝐠 +𝐀𝐰) (𝐭 𝟐 − 𝐭 𝟏 ) (DB Pg 227 Eq 12.63c)
𝟏𝟎𝟑
If 𝐐𝐠 ≤𝐐𝐝 , no artificial cooling required

If 𝐐𝐝 ≤𝐐𝐠 , artificial cooling is required

Amount of Artificial cooling, Q = 𝐐𝐠 - 𝐐𝐝

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