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Worm gears are used when large gear reductions are needed. It is common for worm gears to have
reductions of 20:1, and even up to 300:1 or greater. Power is supplied to the worm gear, which drives
the mating gear. Worm gears usually provide right-angle power flows. The most common use for the
worm gear is in applications where the power source operates at high speed and the output is at slow
speed with high torque. Many steering mechanisms use a worm gear connected to the steering shaft
and wheel and a partial (sector) gear connected to the steering linkage. Small power hand tools
frequently use a high-speed motor with a worm gear drive.

 

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The geometry of a worm is similar to
that of a power screw. Rotation of the worm
simulates a linearly advancing involute rack,
Figure 3

The geometry of a worm gear is similar

to that of a helical gear, except that the
teeth are curved to envelop the worm.

Enveloping the gear gives a greater area

of contact but requires extremely precise


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As with a spur or helical gear, the pitch diameter of a worm gear is related to its circular pitch and
number of teeth T by the formula
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When the angle is 90o between the nonintersecting shafts, the worm lead angle ʄ is equal to the gear
helix angle ʗ. Angles ʄ and ʗ have the same hand.

The pitch diameter of a worm is not a function of its number of threads, Tw.

This means that the velocity ratio of a worm gear set is determined by the ratio of gear teeth to worm
threads; it is not equal to the ratio of gear and worm diameters.

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Worm gears usually have at least 24 teeth, and the number of gear teeth plus worm threads should be
more than 40:

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A worm of any pitch diameter can be made with any number of threads and any axial pitch.

Strength considerations seldom permit a shell worm to have a pitch diameter less than
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The face width of the gear should not exceed half the worm outside diameter.

-+.

Lead angle ʄ, Lead L, and worm pitch diameter dw have the following relationship in connection with the
screw threads.
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 A   has parts similar to a spur gear except for one,
which is called throat diameter. The worm gear usually wraps
slightly around the worm, making its face curve slightly.
Diameter in the center is called throat diameter.
Worm gears can be plain, web, spoked or ring type, same as
spur gears—
Worm gear teeth are in mesh with the thread of the worm.
The endwise movement of the thread moves the gear teeth
past the floating arrow.

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Worm threads are made in even D.P. sizes, measured parallel to worm centerline and the angle of the
thread is called the lead angle or helix angle

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Worm pitch
diameter and worm
gear pitch diameter
just touch when in
mesh

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1. V
  worm gears.
These don't have a  , or groove, machined around the circumference around either the
worm or worm wheel.
2. Single-throated worm gears wherein the worm wheel is throated;
3. Double-throated worm gears wherein both gears throated. This type of gearing can support the
highest loading.
An enveloping (hourglass) worm has one or more teeth and increases in diameter from its middle
portion toward both ends.
Double-enveloping worm gearing comprises enveloping worms mated with fully enveloping worm gears
also known as globoidal worm gearing.

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Unlike with ordinary gear trains, the direction of transmission (input shaft vs output shaft) is not
reversible when using large reduction ratios, due to the greater friction involved between the worm and
worm-wheel, when usually a single start (one spiral) worm is used. This can be an advantage when it is
desired to eliminate any possibility of the output driving the input. If a multi-start worm (multiple
spirals) then the ratio reduces accordingly and the K

  of a worm and worm-gear may need to
be discounted as the gear may be able to drive the worm.
Worm gear configurations in which the gear cannot drive the worm are said to be   

.
Whether a worm and gear will be self-locking depends on the lead angle, the pressure angle, and the
coefficient of friction; however, it is approximately correct to say that a worm and gear will be self-
locking if the tangent of the lead angle is less than the coefficient of friction.








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Helical and worm handedness

A right hand helical gear or right hand worm is one in which the teeth twist clockwise as they recede
from an observer looking along the axis. The designations, right hand and left hand, are the same as in
the long established practice for screw threads, both external and internal. Two external helical gears
operating on parallel axes must be of opposite hand. An internal helical gear and its pinion must be of
the same hand.
A left hand helical gear or left hand worm is one in which the teeth twist counterclockwise as they
recede from an observer looking along the axis.

A worm gear is used when a large speed reduction ratio is required between crossed axis
shafts which do not intersect. A basic helical gear can be used but the power which can be
transmitted is low. A worm drive consists of a large diameter worm wheel with a worm screw
meshing with teeth on the periphery of the worm wheel. The worm is similar to a screw and the
worm wheel is similar to a section of a nut. As the worm is rotated the worm wheel is caused to
rotate due to the screw like action of the worm. The size of the worm gea rset is generally based
on the centre distance between the worm and the worm wheel.

If the worm gears are machined basically as crossed helical gears the result is a highly stress
point contact gear. However normally the worm wheel is cut with a concave as opposed to a
straight width. This is called a single envelope worm gear set. If the worm is machined with a
concave profile to effectively wrap around the worm wheel the gear set is called a double
enveloping worm gear set and has the highest power capacity for the size. Single enveloping gear
sets require accurate alignment of the worm-wheel to ensure full line tooth contact. Double
enveloping gearsets require accurate alignment of both the worm and the wormwheel to obtain
maximum face contact.

  

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Ɍn = Normal pressure angle = 20o as standard

ʄ = Worm lead angle = (180 /ʋ ) tan-1 (Tw / q)(deg) ..Note: for Ɍ n= 20o, ʄ should be less than 25o
Fw = Effective face width of worm wheel. About 2.m я (q +1) (mm)
Fg = Face of worm wheel. About 14*m. (mm)
c = clearance c min = 0.2m cos ʄ , c max = 0,25.m cos ʄ (mm)
Dw = Ref diameter of worm (Pitch diameter of worm (m)) = q*m (mm)
ODw = Tip/outside diameter of worm = dw + 2*aw (mm)
Dg = Ref diameter of worm wheel (Pitch diameter of worm wheel) =( p x*Tg/ʋ ) = 2*aa - dw (mm)
ODg = Tip/outside diameter worm wheel (mm)
aw = Worm Thread addendum = m (mm)
dw = Worm Thread dedendum , min = m.(2,2 cos ɶ - 1 ) , max = m*(2.25 cos ʄ - 1 )(mm)
m = Axial module = p x /ʋ (mm)
m n = Normal module = m cos ʄ(mm)
Tqw = Worm torque (Nm)
Tqg = Worm wheel torque (Nm)
Nw = Rotational speed of worm (revs /min)
Ng = Rotational speed of wormwheel (revs /min)
p x = Axial pitch of of worm threads and circular pitch of wheel teeth; the pitch between adjacent
threads = ʋm (mm)
p n = Normal pitch of of worm threads and gear teeth (m)
q = diameter factor selected from (6 6.5 7 7.5 8 8.5 9 10 11 12 13 14 17 20 )
L = Lead of worm = p x*n (mm).. Distance the thread advances in one revolution of the worm.
EX: For a 2-start worm the lead, L = 2 . p x

R g = Reduction Ratio
q = Worm diameter factor = d w / m - (Allows module to be applied to worm )
ʅ = coefficient of friction
ɻ= Efficiency
Vs = Worm-gear sliding velocity ( m/s)
Tw, n = Number of threads (starts) on worm
Tg = Number of teeth on wormwheel

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Worm gears provide a normal single reduction range of 5:1 to 75:1. The pitch line velocity is
ideally up to 30 m/s. The efficiency of a worm gear ranges from 98% for the lowest ratios to 20% for
the highest ratios. As the frictional heat generation is generally high the worm box is designed that
disperse heat to the surroundings and lubrication is an essential requirement. Worm gears are quiet
in operation. Worm gears at the higher ratios are inherently self locking - the worm can drive the
gear but the gear cannot drive the worm. A worm gear can provide a 50:1 speed reduction but not a
1:50 speed increase. (In practice a worm should not be used as a braking device for safety linked
systems e.g hoists.
The worm gear action is a sliding action which results in significant frictional losses. The ideal
combination of gear materials is for a case hardened alloy steel worm (ground finished) with a
phosphor bronze gear. Other combinations are used for gears with comparatively light loads.
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The sketch below shows the normal (not axial) worm tooth profile as indicated in BS 721-2 for
unit axial module (m = 1mm) other module teeth are in proportion e.g. 2mm module teeth are 2
times larger
Typical axial modules values (m) used for worm gears are:
½ 0.6 0.8 1.0 1¼ 1.60 2.0 2½ 3.15 4.0 5.0 6.3 8.0 10.0 12½ 16 20 25
32 40 50


   

Material Notes applications

Worm
Acetal / Nylon Low Cost, low duty Toys, domestic appliances, instruments
Cast Iron Excellent machinability, medium friction. Used infrequently in modern machinery
Carbon Steel Low cost, reasonable strength Power gears with medium rating.
Power gears with high rating for
Hardened Steel High strength, good durability
extended life
Worm wheel
Acetal /Nylon Low Cost, low duty Toys, domestic appliances, instruments
Reasonable strength, low friction and Normal material for worm gears with
Phos Bronze
good compatibility with steel reasonable efficiency
Cast Iron Excellent machinability, medium friction. Used infrequently in modern machinery
The reduction/speed ratio of a worm gear ( R g )
R g = Tg / Tw
EX: A 30 tooth wheel meshing with a double threaded worm has a reduction of 15

Tangential force on worm ( Ftw )= axial force on wormwheel

Ftw = F ga = 2*Tqw / Dw

Axial force on worm ( F wa ) = Tangential force on gear

Fwa = Ftg = Ftw[ (cos Ɍ n - ʅ tan ʄ ) / (cos Ɍ n . tan ʄ + ʅ ) ]

Output torque ( Tqg ) = Tangential force on wormwheel * Wormwheel reference

diameter /2
Tqg = F gt* Dg / 2
Relationship between the Worm Tangential Force F wt and the Gear Tangential force F gt
F wt = F gt.[ (cos ɲ n . tan ɶ + ʅ ) / (cos ɲ n - ʅ tan ɶ ) ]
Relationship between the output torque M 2and the input torque M 1
Tqg = ( T
Tqw. Dg / Dw ).[ (cos Ɍ n - ʅ tan ʄ ) / (cos Ɍ n . tan ʄ + ʅ ) ]

Separating Force on worm-gearwheel ( F s )

Fr = Ftw[ (sin Ɍ n ) / (cos Ɍ n sin ʄ + ʅ cos ʄ ) ]