Worm Wheel Design Process
Worm Wheel Design Process
Worm Wheel Design Process
The calculation is used for geometrical and strength designs and worm gearing check. The
program solves the following tasks.
1. Calculation of gearing dimensions.
2. Automatic transmission design with minimum input requirements.
3. Design for safety coefficients entered.
4. Calculation of a table of proper solutions.
5. Calculation of complete geometrical parameters.
6. Calculation of strength parameters, safety check.
7. Gearing design for precise centre-line distance.
8. Auxiliary calculations (heating, shaft design).
9. Support of 2D and 3D CAD systems.
The calculations use procedures, algorithms and data from standards ANSI, ISO, DIN, BS and
specialized literature.
List of standards: ANSI/AGMA 6022-C93 (Revision of AGMA 341.02), ANSI/AGMA 6034-B92
(Revision of ANSI/AGMA 6034-A87), DIN 3996, DIN 3975-1, DIN 3975-2
Hint: The comparative document Choices of transmission can be helpful when selecting a
suitable transmission type.
Theory
Application
Worm (globoid) gearing can transmit high outputs, the common ones being 50 to 100 kW
(optimum 0.04kW-120kW, extreme 1000 kW); within one stage, it is able to realize high
transmission ratios i = 5 to 100, (up to i=1000 in kinematical transmissions), being of small size,
low weight, and compact structure. It features quiet and silent operation and can be designed as
a self-locking transmission.
The disadvantage is the large slip in the gearing causing higher friction losses and thereby lower
transmission efficiency; the endeavours for improvement require using deficit nonferrous metals
for wormgear rims. Gearing production is more demanding and expensive and the service life of
such gearing is usually shorter than in rolling gearing.
Worm gearing is used for power transmission in mixers, vertical lathes, vehicles and lifting
equipment, textile machines, presses, conveyors, shears, drums, hoists, ship propeller drives,
planers, machine tools, cars...
This calculation deals with the most frequently used gearing with cylindrical worm and globoid
gear.
Geometry
Worm gearing is a special case of screw gearing with the angle of axes 90 and a low number of
pinion/worm teeth (mostly z1=1-4). Worm gearing types are distinguished by shape as follows:
1. Cylindrical wheel/cylindrical worm (kinematical, non-power transmissions, low torque,
manual drive, adjusting mechanisms, point contact of teeth, cheap production)
2. Cylindrical worm/globoid wheel most frequent (power transmissions, compact design,
divided by cylindrical worm shape see below)
3. Globoid worm/cylindrical wheel (not used)
4. Globoid wheel and worm (high outputs, compact design, special production, highest
quality, high price)
ZA wormgear with straight-line (trapezoidal) tooth profile in axial section; the tooth
sides are slightly convex in the normal section; the cross section results in the spiral of
Archimedes. The elements in the axial section are usually standardized, i.e. mx=m, x=.
The gearing is produced using lathes or thread-cutting machines (the worm resembles a
motion screw with trapezoidal threads). A tool shaped as the basic profile is applied onto the
workpiece in the axial plane. With larger angles, different cutting angles occur in the
forming tool on the lateral edges, which results in unequal cutting edge loading and blunting.
The lateral worm areas can only be sharpened using a special form grinding wheel. Therefore,
spiral gearing is used in worms with a low pitch angle (<10) in those cases when tooth
sides are not treated thermally and do not require regrinding.
Thermally treated sides can be ground using a grinding wheel with straight-line bevel areas
on thread grinding machines; this grinding process results in non-straight-line lateral areas
which, however, rather approximate the theoretical ones. If also the screw milling cutter used
to produce worm gear toothing is subject to this grinding process, the worm and the worm
gear create a theoretically proper pair. The common gearing is also suitable for worms with
greater angles
and for worms with thermally treated tooth sides that require regrinding.
ZI worm with an evolvent profile (a straight-line tooth profile in a plane tangential to the
main cylinder). The tooth sides are convex in both the centre-line and normal sections and
the cross section results in an evolvent. The elements in the normal plane are standardized,
i.e. mn=m, n=. The gearing is worked using two tools applied onto the workpiece. The tool
cutting edge lies in the tangent direction towards the helix on the main cylinder. The evolvent
gearing is used in worms with a higher number of teeth, e.g. z1>4; the worm resembles a
cylindrical gear with helical teeth. Tooth sides can be ground with the flat side of the grinding
wheel; special grinding machines must be used given the relatively small angle .
Note: The worm type options depend particularly on the production possibilities and
transmission used. Detailed information is available in professional and the firms literature.
Formulas (geometry calculation)
The formulas given in this article are used in geometry calculation.
3. Rolling diameter
ZA: dw1=d1+2 x mx; dw2=d2
ZN: dw1=d1+2 x mn; dw2=d2
4. Equivalent diameter: dwe2=2 a - d2
5. Mean diameter: DIN (10): dm1=2 a - dm2; (11) dm1=q mx
6. Tip diameter
ZA: da1=d1 + 2 ha* mx; da2=d2 + 2 (ha* + x) mx; dae2 = da2 + 2 v mx
ZN: da1=d1 + 2 ha* mn; da2=d2 + 2 (ha* + x) mn; dae2 = da2 + 2 v mn
7. Root diameter
ZA: df1=d1 - 2 (ha* + c*) mx; df2=d2 - 2 (ha* + c* - x) mx
ZN: df1=d1 - 2 (ha* + c*) mn; df2=d2 - 2 (ha* + c* - x) mn
8. Addendum
ZA: ha1=ha* mx; ha2=(ha* + x) mx
ZN: ha1=ha* mn; ha2=(ha* + x) mn
9. Dedendum
ZA: hf1=(ha* + c*) mx; hf2=(ha* + c* - x) mx
ZN: hf1=(ha* + c*) mn; hf2=(ha* + c* - x) mn
10. Pitch angle
ZA: tan()=mx z1 / d1 = z1 / q
ZN: tan()=mx z1 / d1 = z1 / q
Note: Article [12] provides the calculation of dimensions as per AGMA 6022-C93. Since the worm
gearing design permits considerable liberty, some of the dimensional parameters may differ in
both calculations as either of the standards may recommend different parameter options, namely
tooth profile [3.0] and worm diameter parameters [4.11].
Force conditions.
The following formulas are used to calculate the forces occurring in toothing.
z = tan() / tan(z)
where:
...pitch angle
...friction angle =atan()
As the pitch angle increases (with given friction angle), efficiency rises quickly at first to change
into a flat curve and drop quickly again (see the Figure).
The curve peak is in the middle of the interval [0; 90-] and the theoretical maximum efficiency
of a worm gearing is then calculated as follows:
max =
tan(45/2) / tan(45/2)
The vertical axis shows gearing efficiency, the horizontal axis shows the pitch angle, and
individual curves are for different friction coefficients.
In practice, pitch angles up to 10 and up to 20-25 are used for worms ZA and for common
worms ZN, ZI respectively, namely for production reasons. Endeavours after the highest possible
efficiency then result in using higher pitch angles, which can be achieved by reducing worm
diameter and using multiple worms.
Wheel is the driving member
This design is virtually not used in power transmissions.
Efficiency of gearing:
z = P1 / P2 = tan() / tan()
Self-locking feature
In this case, the point of intersection of the curve with the horizontal axis (red circled), which
defines the self-locking limit, is important. It is the moment when gearing cannot be moved using
even the highest possible torque acting on the worm gear (this feature is used in lifting
mechanisms, for instance). The self-locking limit occurs when the pitch angle equals to the angle
of friction.
In practice, the following self-locking features are used as a minimum:
Static the static friction coefficient is considerably higher than the dynamic one (2 or
more times); therefore, static self-locking occurs typically at 5-8;
Dynamic dynamic friction coefficient where self-locking typically occurs at 1-3 should
be taken into account on vibrations or shocks in the transmission.
Friction coefficient
Friction coefficient has the highest effect on transmission efficiency. It depends on a number of
parameters (material, surface, lubricant, speed, size). It is calculated using the following formula:
ges = Pw2 / (Pw2 + PV), where PV is total power loss; line calculation [6.9-6.15]
Wear load capacity SW
Abrasive loss of material occurs during gearing operation, which means that tooth thickness is
reduced. This predominantly affects the tooth side made of a material of lower hardness (wheel
as a rule). A number of tests were performed recently with different materials, dimensions and oil
types, giving the results as shown on the Figure.
load cycle
loading intensity
Permissible wear
Wlimn..
Permissible wear of worm gear Wlimn depends predominantly on the equipment in which the
worm transmission is used. It may be determined by the maximum backlash in the gearing, for
instance. In any case, however, permissible wear is achieved at the tooth sharpness limit. If no
particular conditions are agreed/determined, the following is considered as a rule:
Worm: 16MnCr5E; Wheel: CuSn12Ni-GZ; Syntetick olej; n1=500; i=20; Hm = 330 MPa
Curves: A) a=160 [mm]; B) a=100 [mm]; C) a=65 [mm]
The following basic formulas are used to check safety:
Contact stress
Hm
HG
Pitting safety SH
SH =
HG / Hm SHmin (SHmin=1.0)
It can be influenced (increased) by choosing lower service life required [2.12], oil of higher grade
[2.7] and, of course, through the choice of geometrical parameters.
Worm deflection (DIN 3996)
Too great and dynamically changing worm deflection may result in interferences and thereby in
increased wear.
Worm shaft deflection
Hint: The calculation module for shaft design and check can advantageously be used for the final
precise establishment of worm shaft deflection and its more detailed analysis.
Permissible worm shaft deflection
FG = Flim YNL
Worm: 16MnCrSEh; Wheel: GZ-CuSn12Ni; polyglycol (EO:PO=0:1); a = 180 mm; n1 = 500 rpm; L
= 25000 h
Calculation procedure.
Gear transmissions are split into:
Power gearing The gearing intended predominantly for power transfer and transformation
must be designed/checked for strength (e.g. machine drives, industrial gearboxes).
Non-power gearing No strength design/check needs to be performed in gearing where the
torque moment is minimal given the wheel size (e.g. instrumentation, regulation equipment...).
Power gearing design.
Any worm gearing design provides considerable liberty in selecting gear diameters and width.
Therefore, the calculation makes it possible to create a table of proper solutions to pick from a
number of parameters, such as weight, centre-line distance, efficiency, etc.
Design procedure:
The result of this procedure is a table of proper solutions of the gearing being designed.
1. Enter transmission power parameters (transmitted power, speed, required transmission
ratio). [1.0]
2. Select pinion and wheel material, loading conditions, operating and production
parameters, and safety coefficients. [2.0]
3. Select tooth profile parameters [3.0]
4. Select the marginal parameters for the calculation of the table of proper solutions.
[4.2,4.3,4.4,4.5]
5. Press "Run the table".
6. Select that solution which suits your requirements best from the table [4.7].
7. Check the results.
Parameter optimization:
Although the solution table provides correct proposals, it is advisable to optimize and fine-tune
some parameters, namely centre-line distance [4.23,4.24] and worm bearing distance
[4.16,4.17].
Gearing design for precise centre-line distance:
The following procedure is most appropriate in power gearing:
1. Carry out a standard design (see above)
2. Sort the solution table by centre-line distances [4.5]
3. Select the centre-line distance nearest to your required centre-line distance in the solution
table
4. Fine-tune the centre-line distance [4.23,4.24]
An auxiliary calculation [16.0] can be used for non-power gearing.
Non-power gearing design.
No strength parameters need to be addressed and checked when designing a non-power gearing.
Therefore, directly select the proper number of teeth and a module [4.8-4.20] and check the
dimensions of the gearing being designed.
Hint: When designing a non-power gearing, select an appropriately low power to be transmitted.
Worm deflection
Oil heating
These conditions must be reflected when choosing the worm and gear materials. Hardened and
ground worm mating with tin or phosphorus bronze gear is mostly selected.
Material of worm gear
The basic material is bronze, less frequently being cast iron or brass. Plastic gears are used for
lower powers (to absorb shocks and provide lower noise) and non-power gearing. Bronze gears
are manufactured as composite for economical reasons (a bronze rim put on a steel or cast-iron
wheel). Centrifugal casting is advisable.
The optimum options are tin bronze with high Sn content of 10-12% (excellent friction properties,
high resistance to seizure and good running-in), but are too expensive. Their application can only
be justified in loaded transmissions and with sliding speed exceeding 10 m/s. Even in these
cases, however, there is an effort to replace them by Sn-Ni bronze and other alloys. Bronze with
lower Sn content (5-6%) can be used for speed v = 4-10 m/s.
Less expensive bronze free from tin, e.g. aluminium or lead bronze, or brass are suitable for
speeds v<4 m/s. They are relatively hard and strong, but are less resistant to seizure and are not
so good for running-in. The mating worm, therefore, must have high surface hardness (HRC>45).
In gearing with a greater worm gear, a combination of bronze worm and cast-iron gear can be
used for economical reasons.
Grey cast iron mated with a steel worm can be used for low outputs, quiet load and low
peripheral speed up to 2 m/s.
Material of worm
Carbon or alloyed steel which allows surface heat hardening (hardening to HRC 45-50, cementing
and hardening to HRC 56-62, and nitriding) is used for worms. Tooth sides are ground and/or
polished. When nitrided, the material need not be ground and polished only. Heat-treated or
normalized steel worms are only used for lower outputs and lower peripheral speeds.
Customers own material values If a material which is not specified in the table of materials
should be used for gearing, a number of data should be entered about the material. Go to the
sheet Materials. The first 5 lines in the materials table are reserved for defining the customers
own materials. Enter the material name in the pertinent column (will be shown in the options
menu) and fill in all parameters in the line (white boxes) gradually. After that, go to the
Calculations sheet, select the newly defined material and continue the calculation.
Warning: Customers own material values must be entered in the SI units (MPa,GPa).
Warning: Calculation to DIN 3996 is based on worm gearing research and tests for a hardened,
cemented worm made from 16MnCr5 (DIN EN 10084) and a worm gear made from the following
materials: Bronze - CuSn12-C-GZ, CuSn12Ni2-C-GZ (centrifugal cast), CuSn12Ni2-C-GC
(continuous casting), CuAl10Fe5Ni5-C-GZ (DIN EN 1982), grey cast iron EN-GJS-400-15 (DIN EN
1563), EN-GJL-250 (DIN EN 1561). The results must be transposed in a suitable manner for other
materials.
2.3 Type of worm
Select the type of worm. For details on worm types see the theoretical section of the Help.
2.4 Gearbox loading, driving machine - examples.
Setting of these coefficients substantially affects the calculation of safety coefficients. Therefore,
try to enter as accurate a specification as possible when selecting the type of loading. Examples
of driving machines:
A. Continuous: electric motor, steam turbine, gas turbine
B. With light shocks: hydraulic motor, steam turbine, gas turbine
Total losses reduced by 30% and more (smaller and more economical driving unit)
These advantages are opposed by higher price, possible problems with the plastic or rubber
parts, and limited miscibility with mineral oils.
2.8 Oil designation - selection
In the menu, oils are ordered by ISO (AGMA) viscosity. By selecting oil from the menu, selected oil
parameters are transmitted to corresponding boxes (viscosity at 40 C, viscosity at 100 C,
specific weight [kg/dm^3]). If oil parameters are known from the manufacturers material sheet,
enter the parameters in the appropriate boxes [2.9,2.10].
Table: Recommended values for viscosity selection in [mm^2/s] (cSt)
Bulk temperature [C]
Max. working
Starting
< 2.5
2.5 ... 5
>5
0 - 10
-10 - 0
110 130
110 130
110 130
0 - 10
>0
110 150
110 150
110 150
10 - 30
>0
200 245
150 200
150 200
30 - 55
>0
350 510
245 350
200 245
55 - 80
>0
510 780
350 510
245 350
80 - 100
>0
900 1100
510 780
350 510
EP
VG 46
2 EP
VG 68
3 EP
VG 100
4 EP
VG 150
5 EP
VG 220
6 EP
VG 320
7 7comp
7 EP
VG 460
8 8comp
8 EP
VG 680
8A comp
9
VG 1000
9 EP
VG 1500
Durability
2000
5000
20000
40000
80000
150000
The range of permissible values is z1=1~12, the first value being lower than or equal to the
second one.
4.4 Range q from - to
In this line, enter the range of diameter quotient q for which the table should be solved. Usually
q=8-16 (higher value q for smaller module).
The range of permissible values is q=6~25, the first value being lower than or equal to the
second one.
4.5 Sort results by parameters
Choose by which column the table has to be sorted.
4.6 Table of solutions
By selecting a solution from the table, the solution parameters are transferred into the
calculation. The small push-button "<" on the right will transfer the values from the actual table
line into the calculation.
The table includes the following parameters:
i - Transmission ratio
q - Diameter quotient
m - Module
DP - Diametral pitch
a - Center distance
d1 - Reference diameter
d2 - Reference diameter
Warning: The values of transmission ratio [1.6], pressure angle [4.10] and addendum
modification coefficient for worm gear [4.21] are also entered in the table of proper solutions.
When selected from the table [4.7], these values are set for the saved values. Therefore, when
changing the parameters, recalculate the table of proper solutions.
4.8 Design of a geometry.
In this section, one can define directly all important worm gearing parameters which influence
and define its geometry. The description and importance of individual parameters are specified
for each of them.
4.9 Number of teeth of Worm/Worm Gear
Enter the number of teeth of worm. The value commonly used ranges from 1 to 4, in special
cases up to 12. It is recommended to select the proper number of teeth from the table of
solutions [4.6] on the basis of your optimization requirements (e.g. weight, efficiency, centre-line
distance ...). In any case, it is advisable to consult manufacturing possibilities with the
technologist.
The number of worm gear teeth is calculated on the basis of the required transmission ratio. The
number of gear teeth must acquire a certain minimum value; otherwise, tooth undercut would
occur. If this is the case, the minimum value is shown in brackets and the box text is shown in
red.
Hint: The minimum number of worm gear teeth can be changed by suitable correction [4.21].
Hint: If you know the numbers of worm and wormgear teeth and need to calculate the
transmission ratio, press the push-button on the right from the entering field and make the
calculation in the Additions Section.
4.10 Pressure angle
Axial pressure angle is entered for the ZA type worm, while normal pressure angle is entered for
other types (ZN,ZI,ZK,ZH). Pressure angle is selected from 15 to 30.
The value of 20 is commonly used. Pressure angle can be selected in dependence on the
requirements for the equipment being designed. Greater pressure angle results in higher safety
against fatigue break (SF) and lower danger of gear tooth undercut. On the other hand, greater
pressure angle reduces the number of engaged teeth, increases bearing load and the worm
deflection load (greater worm deflection). Pressure angle can also be selected in dependence on
pitch angle [4.13], the greater being the pressure angle, the greater pitch angle is chosen.
Minimum number of gear teeth in dependence on pressure angle at zero gearing correction (table
in Help).
Pressure angle
[]
Min. z2/NG
14.5
40
17.5
27
20
21
22.5
17
25
14
27.5
12
30
10
module value (mx or mn), unless a certain value of pitch angle is required. In the effort towards
the least possible number of screw cutters for manufacturing work gears, the manufacturers
recommend choosing d1=qm, where q is the coefficient depending on the size of standardized
module m. In consideration of worm rigidity in bending, greater values q are assigned to lower
values m.
m
2.5
10
12
16
20
25
16
12
12
14
10
10
10
10
10
12
12
12
10
14
14
14
12
Note: Since diameter quotient, worm diameter and pitch angle [4.11, 4.12, 4.13] correlate, each
of these values can be entered. Tick the selection push-button on the proper line to select the
entry.
4.12 Worm pitch diameter
d1=qm
If you require entering a precise worm diameter value, activate the entry field by ticking the
selection push-button. The recommended approximate value d1 in dependence on the module
and on the number of worm teeth is given on the right of the entry field.
Note: Since diameter quotient, worm diameter and pitch angle [4.11, 4.12, 4.13] correlate, each
of these values can be entered. Tick the selection push-button on the proper line to select the
entry.
4.13 Pitch angle
Pitch angle is one of the key parameters of worm gearing closely related to worm dimensions and
transmission efficiency. Efficiency grows with increasing pitch angle (for detailed information see
the efficiency section).
The important pitch angle is at the self-locking limit (friction angle [6.8] is equal to pitch angle).
This angle is filled in after pressing the "<=SL" push-button on the right.
Recommended value:
6-40 in worms manufactured from one piece
do 17 in worms put on a shaft
Hint: Since the selection of parameters allows considerable liberty, it is not easy to choose all
parameters manually at once. It is therefore recommended to choose such a solution from the
table of proper solutions which meets ones requirements best, use the solution and fine-tune
individual parameters gradually.
Note: Since diameter quotient, worm diameter and pitch angle [4.11, 4.12, 4.13] correlate, each
of these values can be entered. Tick the selection push-button on the proper line to select the
entry.
4.14 Pitch direction
Select pitch direction. It only has an effect on force orientation and sense of rotation. Unless the
drive kinematics require otherwise, the worm has the right sense of rotation.
4.15 Module/Standardized value/Diametral Pitch (module reverse value)
Module (DP) is the key parameter which affects the gearing size and, thereby, pertinent safety
coefficients. The following entries are required in dependence on the selected calculation units
[1.1]:
SI units (N, mm, kW)
Gearing module is required, axial mx for ZA worm type and normal mn for other types
(ZN,ZI,ZK,ZH).
Imperial units (lbf, in, HP)
The DP value (Diametral Pitch) is required.
The table value can be selected from the options menu on the right.
4.17, 4.18 Distance of left/right bearing
Bearing distance from worm centre (see the Figure) has a direct impact on worm deflection and
thus on worm deflection safety. In the line [4.17] enter the distance of the left and right bearing
from the gear centre as percentage of worm gear outer diameter. This method of selection is
used automatically when calculating the table of proper solutions [4.6]. If you require entering a
precise value, clear the ticking box on the line [4.18] and enter the precise value.
For every method, the range of possible parameter change is specified in brackets "<>" and the
range of possible change in axis distance is specified in parentheses "( )".
4.26 Approximate weight of the gearbox/gears
The first box shows the weight of the complete gearbox (the sum of weights of gear wheels,
shafts and gearbox body). The second box provides the weight of the worm and gears including
shafts. Cast iron is considered as material for gearbox weight calculation.
Note: Although the calculation is approximate only, it provides a suitable optimization
parameter.
4.27 Total efficiency/Max. theoretical
The first box shows the total efficiency of the actually designed gearing, while the right one
shows the maximum theoretically possible efficiency for the actual conditions (lubrication,
materials, bearings, etc.).
Total efficiency is affected most by pitch angle [4.13], when higher pitch angle results in higher
efficiency.
Hint: More information is provided in the theoretical section.
Note: Achieving the highest efficiency will be favourable in most designs. It is therefore a
suitable optimization parameter.
Wlim=0.3 mx cos(m)
Permissible wear is shown in the green box, while the actual value appears automatically after
activating the ticking box.
7.19 Wear safety
It can be controlled (increased) by choosing lower required service time [2.12], oil of higher
grade, higher viscosity [2.7,2.8] and, of course, selecting geometrical parameters.
importance for correct design, which would ensure gearbox function within the permissible oil
temperature range.
The first section provides thermal safety calculation to DIN 3996, method C, while the other
includes a worm gearing thermal analysis. More detailed information is available in the
theoretical section of Help.
Warning: Any change in gearbox temperature parameters or oil temperature results in oil
parameter change, which affects the calculation of safety coefficients SW and SF. It is
recommended to re-check the coefficients.
11.1 Ambient air temperature
Enter ambient air temperature, usually 20C [68F].
11.2 Extreme temperature of gearbox (oil)
The usual maximum temperatures are for:
Temperature appears automatically according to the oil type selected. If you want to enter your
specific value, clear the ticking box.
11.3 Cooling of gearbox
Select whether a fan is attached to the worm shaft or the gearbox has no fan.
Note: It is advisable to use a fan when the speed exceeds 800 rpm.
11.5 Oil bath lubrication, method C
According to DIN 3996, it is possible to use an approximate formula to calculate the temperature
of a well-ribbed gearbox for cast-iron gears with centre-line distance 63-400 [mm], worm speed
60-3000 [rpm] and transmission ratio 10-40. A deviation of 10K from the actual value should
be taken into account.
The approximate formula result shows gearbox temperature [11.6] and thermal safety [11.7],
which should be higher than 1.1.
11.8 Thermal analysis
This section enables making a simple thermal analysis of a gearbox. Most input parameters are
estimated on the basis of size, power transmitted, design type and others. But more precise
values can also be used, obtained from measurement on a similar gearbox or from the
professional literature, for instance. Clear the ticking box in the pertinent line to enter a specific
value of a required parameter.
Note: Unless oil-spray lubrication [2.6] is selected, pertinent partial calculation [11.14-11.18] in
this section is highlighted in grey and is not included in the result.
11.9 Requested max. temperature of gearbox (oil)
It is proposed on the basis of oil used so as to achieve thermal safety coefficient 1.1.
11.10 Ribbing of the gearbox
Select the type of gearbox surface (design) in the options menu. The parameter has an impact on
surface estimate [11.11].
11.11 Gearbox surface
Surface area is achieved by an approximate calculation based on gearing dimensions. It is
advisable to use a suitable output from the CAD 3D model for precise calculation (check).
11.12 Heat transfer coefficient
Heat transfer (transmission, radiation) coefficient depends on the gearbox operation environment
(ventilation, room size), gearbox size, ribbing, number of worm speed, temperature, etc. The use
of a fan can triple the coefficient. Any precise calculation of the coefficient is therefore difficult
and requires a thorough analysis. Values from 5 [W/m2*K] to 50 [W/m2*K] were measured in
practice. If the ticking box is crossed, an approximate value estimated based on gearbox speed,
size and design is added automatically.
Recommended values:
Basic values for box without fan:
- Small unventilated rooms ...8-12 [W/m2*K]
- Well ventilated rooms ...14-20 [W/m2*K]
Fan effect: The use of a fan may increase the coefficient by up to 100%
Size effect: Small gearboxes may have the coefficient up to 50% higher than big ones
Temperature effect: The coefficient may increase by up to 15% with the difference of ambient
temperature and oil temperature increasing
Speed effect: The coefficient increases with worm speed increasing
11.13 Oil cooler power (inside/outside) if used
In gearboxes where the loss heat is higher (higher power, lower efficiency), natural cooling is
often insufficient and additional oil cooling must be used in the form of an external oil cooler or a
cooling worm in the gearbox. This line shows the loss power necessary to achieve the required
temperature [11.9]. If additional cooling is not required, the value is zero.
Note: If oil-spray lubrication method is specified in line [2.6], zero value is entered and the
following lines are used to calculate additional cooling.
11.14 Oil-spray lubrication
If oil-spray lubrication is selected [2.6], the volume of oil supplied by the pump can be proposed
in this section.
11.15 Use of oil cooler
Specify in this line whether or not an oil cooler is used. Oil cooler application has an effect on the
temperature difference of the lubrication oil.
11.16 Temperature difference of the lubrication oil
It is the difference of temperatures between oil drawn by the pump and sprayed oil.
The usual values are as follows:
A strength calculation (check) according to AGMA is given here to have the full picture. In
comparison with the calculation to DIN, the one to AGMA is much simpler, comprising less input
parameters. This, of course, has an impact on calculation accuracy. It is therefore recommended
to use the check to DIN, which is more precise and describes the worm gear behaviour better.
Comparison of both is in the theoretical section.
Forces are generated in loaded gearing and transmitted to the machine structure. The knowledge
of these forces is quite crucial for proper dimensioning. Force orientation is shown on the figure
and force magnitudes are specified in this article [14.1-14.6].
http://www.mitcalc.com/doc/gear4/help/en/gear4.htm