Housing

The choice of worm gear housing – cast iron or cast aluminum – influences factors
such as size, heat dissipation, and resistance to harsh conditions.

OBSERVATON

The manufacturing process used is the casting.

Advantages:
Casting has following advantages over other manufacturing process.
 It can create any complex structure economically.
 The size of object doesn’t matter for casting.
 The casting objects have high compressive strength.
 All structure made by casting has wide range of properties.
 This can create an accurate object.
 All material can be cast.
MANUFACTURING  It creates isotropic structure.
PROCESS  It is cheapest among all manufacturing processes.
 Composite component can be easily made by casting.

Disadvantages:
Along these advantages, casting has following disadvantages.
 It gives poor surface finish and mostly requires surface finish operation.
 Casting defects involves in this process.
 It gives low fatigue strength compare to forging.
 It is not economical for mass production.

The iron or aluminum is used as cast ability material. Both of the material has really
good cast ability. Steel is preferred than aluminum as some properties in steel like
Hardanability and Brittleness helps material to become more resistive.
MATERIAL
REALATIONSHIP
 WORM GEAR

The material used for the worm gear drive is the Aluminum or Bronze. Worm gear
need to be softer than the worm shaft that why aluminum is used.
OBSERVATON

The worm gear manufactured by using Die Casting. The finishing operation done by
the Hobbing process. Hobbing is the gear generation process most widely used in
gear cutting.

Advantages:
The casting insures the shape and size as per requirements.
 The size of object doesn’t matter for casting.
 The casting objects have high compressive strength.
MANUFACTURING
 All structure made by casting has wide range of properties.
PROCESS
 This can create an accurate object.
Hobbing process creates the shape of teeth as like hob or worm.

Disadvantages:
 It gives poor surface finish and mostly requires surface finish operation.
 Casting defects involves in this process.
 It gives low fatigue strength compare to forging.
It is not economical for mass production.
Aluminum is not bad for casting. It is good for hobbing while finishing.

MATERIAL
REALATIONSHIP
 WORM SHAFT

The material used here will be Hard Steel, Stainless Steel, case hardened steels and
tempered steels.

OBSERVATON

The manufacturing process will be Forging.

Advantages

1. Forged parts possess high ductility and offers great resistance to impact and
fatigue loads.
2. Forging refines the structure of the metal.
3. It results in considerable saving in time, labor and material as compared to the
production of similar item by cutting from a solid stock and then shaping it.
4. Forging distorts the previously created unidirectional fiber as created by rolling
and increases the strength by setting the direction of grains.
5. Because of intense working, flaws are rarely found, so have good reliability.
6. The reasonable degree of accuracy may be obtained in forging operation.
MANUFACTURING 7. The forged parts can be easily welded.
PROCESS
Disadvantages

1. Rapid oxidation in forging of metal surface at high temperature results in scaling

which wears the dies.
2. The close tolerances in forging operations are difficult to maintain.
3. Forging is limited to simple shapes and has limitation for parts having undercuts
etc.
4. Some materials are not readily worked by forging.
5. The initial cost of forging dies and the cost of their maintenance is high.
6. The metals gets cracked or distorted if worked below a specified temperature
limit.
7. The maintenance cost of forging dies is also very high.

Steel is the best material for forging. Steel fulfills the all kind of requirements that
require for forging operation. All abilities like hardnability, durability, toughness it
has.
MATERIAL
REALATIONSHIP