UNIT 11 HELICAL, BEVEL AND

WORM GEARS
Structure
1 1.1 Introduction
Objectives
1 1.2 Nomenclature and Forces
1 1.3 Surface Strength and Helical Teeth
1 1.4 Beam Strength of Helical Tooth
1 1.5 Load Factors
1 1.6 Bevel Gears
1 1.7 Forces in Bevel Gear
11.8 Surface Strength of Tooth in Bevel Gear
11.9 Beam Strength of Bevel Gear Tooth
1 1.10 Worm and Worm Gears
1 1.1 1 Geometry and Velocity Ratio
1 1.12 Forces in Worm and Worm Gear
1 1.13 Designing of Worm Wheel
1 1.14 Summary
1 1.15 Key Words
1 1.16 Answers to SAQs

11.1 INTRODUCTION
The gears were introduced in Unit 10. The design of straight tooth spur gear was
developed from first principles. It is desirable that you should get clear understanding of
gear classification. The classification is based on the two shafts on which gears are
mounted. In this class of gear two types are possible. Straight tooth gears have their teeth
parallel to shaft axis. Helical gears have teeth inclined to shaft axis at angle of helix.
Bevel gears have intersecting shafts. Worm gears mate with worms which are like
threads. The shafts of worm and worm gear are in parallel planes but perpendicular to
each other.
The design of all these gears follow the same basic premises that teeth can fail either due
to surface compressive stress or due to bending of teeth. The formula that were derived
for straight tooth spur gears can be modified to suit the changed geometrical conditions.
In each case the understanding has to develop how the forces will act on teeth and how
they will be transmitted to the shafts.
Objectives
After studying this unit, you should be able to
make clear distinction between types of gears,
calculate forces on gear teeth,
design helical, bevel, worm gears and worms, and
choose various materials to make gears.
Design of Power
Transmission Devices 11.2 NOMENCLATURE AND FORCES
In Section 10.1 1 of last unit helical gear was introduced and some terms pertaining to
helical gear were described. Also the force analysis to calculate force on the helical gear
was done. These are repeated in brief and reference is made to Fi'gure 10.17.
The tooth length or face width in helical gear is larger than the width of gear which is
measured parallel to the gear axis. Apparently the difference between the tooth face
width and gear width will depend upon the helix angle P. The normal circular pitch and
normal module denoted respectively by p,,, and m,, are quantities measured perpendicular
to the tooth line whereas transverse circular pitch (p,,) and transverse module (m,) are the
quantities measured along the circumference of the gear or perpendicular to the axis
(Figure 10.17).
The Eq. (10.13) gives the relationship.
m, = m, cos p . . .(11.1)
If a helical gear is cut by a plane perpendicular to the teeth an ellipse of radius of
r
curvature of --- at the pitch point will be obtained, r is the radius of curvature at the
cos2 p
pitch point if gear is cut by plane perpendicular to the axis. If a circle is drawn with a
r
radius of -and on it are placed teeth of module m,, the resulting tooth profile is
c0s2 p
same as the profile of the helical tooth in the normal section. The former may be called
an equivalent or virtual gear and the number of teeth on this gear is called equivalent or
virtual number of teeth denoted by Zv, Eq. (10.16) is reproduced here.

Zvis purely imaginary and will be used for calculations only.

The forces acting on a helical gear are :
Tangential force = P
Axial force = Pa
Radial force = P,
Eqs. (10.10), (10.17), (10.18) and (10.19) are reproduced.

tan P
19100 H -
P, =
Nd cos p
19100 H
Also P, = tan a,
Nd
Here H i s the power transmitted (kW), d is pitch circle diameter (m), a,,
is the pressure
angle in plane normal to the tooth and a,is the pressure angle in transverse plane.
The main advantage of the helical gears is that the profiles of teeth come in contact
gradually along the contact line both over the face width and depth of the tooth
(Figure 11.l(a)). The contact ratio in helical gear is quite high as compared to that in the
straight tooth gear. As many as 10 pairs of teeth may be in contact simultaneously
 depending upon angle P. Such high contact ratio makes the gear operation smooth and Helical, Bevel and
Worm Gears
shock free and the noise is reduced considerably. As a result the dynamic load on the
I helical gear is much less than in case of straight tooth gear, permitting higher peripheral
I velocities. These speeds could as large as 60 to 70 mls.

(a) A Pairs of Helical Gears

(b) Double Helical gears Mounted on the Same Shaft. Axial Reaction is Neutralised

(c) Herringbone Gear Neutralises Axial Reaction

Figure 11.1

Apparent disadvantages of a helical gear is the axial load P, given by Eq. (1 1.4). This
force may be eliminated by using gears of opposite helix angles side by side or gear
which has teeth cut in opposite directions as herringbone gear. A herringbone gear has
teeth cut in opposite inclined direction on a gear blank. It has the advantage of increased
face width. Figures 1I . 1(b) and ( c ) shows two helical gears placed side by side and a
herringbone gear, respectively.
When a number of teeth pairs make contact simultaneously the effective contact length of
face width in helical gear will increase in comparison with a straight tooth spur gear of
same transverse face width. The factor by which the effective face width increase may be
denoted by u, such that
Effective face width = u b . . . (i)
1
where UoC- . . . (ii)
c0s2 p
To increase u one may recommend to increase p. But looking at Eq. (1 1.4) one can see
that higher value of P will result in higher axial reaction. To make a compromise, value
of p is often selected between 8" and 20" though in cases of double helical gears and
herringbone gear P can be as high as 45".
Design o f Power The normal value of pressure angle in case of helical gear is 90" in the plane normal to
Transmission Devices the teeth and gear properties are calculated based upon this angle and normal module.

11.3 SURFACE STRENGTH OF HELICAL TEETH

The basic force mechanics in case of helical gear and straight tooth gear is same. Using
Hertz contact stress formula the expression for maximum compressive stress on tooth
surface was derived in Section 10.13 and mentioned in Eq. (10.25). The same equation is
reproduced here after introducing a total design load factor K and modifying the face
width b by multiplying with u. It has been pointed out earlier that the factor u is
approximately 1.35.

All notations have been same meaning as already stated in last unit. Eq. (10.7) may be
written as

If permissible surface stress, as given in Table 10.10, is denoted by a,,, the design
equation for centre distance, A will be

Here H is measured in kW,a,,, in Pa,N, in rpm. To obtain A in m, ~ J may

A be chosen
between 0.2-0.6 for helical gears and between 0.4-1.2 for double helical and herringbone
gears.
The pitch circle diameter in transverse planes are given by the same formula as for
straight tooth spur gears.

2, in the first of the above equations

Using i = -
P

2 A cos P
or m, =
2, + 2,"

The normal module, m,, can be chosen over a wide range of (0.01 to-0.02) A.
 Helical, Bevel and
Worm Gears

The bending strqss in the tooth of a helical gear can be calculated by Eq. (10.3 1) of last
unit. To adop<thi%iquationfor a helical tooth m, b and a are respectively replaced by m,,
1.35 b and a,,. m, is subsequently replaced by - mn
cos p '
The Eq. (10.3 1) is first reproduced here,
.?r
19100 K H 1
-
a= .
N x 1.35 b d, cos a, m, Y
Here dv is the diameter of virtual pitch circle on which the profile of tooth of module m,,
coincides with the profile of normal tooth cross-section. Reference Figure 10.17(b),
Eq. (10.15) and Section 11.1.
d
But d, =-
c0s2 p

d = m s Z = - mn Z
cos p

Hence, d, =- mn Z
cos p
L
But Z, = -= virtual or equivalent number of teeth on a gear of diameter d,.
COS~ p
Hence, d , = m, Zv
Using b=mn ym

and a, = 20' or cos a, = 0.94

19100 KH 1
-
Now o=
1 . 3 5 0~ . 9 4 ~N y m m: Z, ' Y

The tooth from factor Y is chosen for number of teeth Zv, from Eq. (10.32). m, will be
measured in m. Eq. (10.1 I ) is used to calculate design of working stress in the tooth of
the helical gear and for safe design o < ob where ob is the permissible stress. W, is chosen
to lie between 20-30 for open drive and between 40-60 for closed drive.
Eq. (1 1.1 1) is transformed into a design equation to calculate m,, i.e.

The permissible stress ob is given by

where K, is fatigue strength reduction factor and n, the factor of safety (Table 10.15).
Comparison of Eqs. (10.28) and (I 1.8) for centre distance and of Eqs. (1 0.33) and
(1 1.12) for normal module will suggest that a helical gear drive will be smaller than a
straight tooth spur gear drive for same power and rpm. Yet another factor that tends to
reduce overall gear dimensions is the dynamic load factor Kdwhich is less in case of
helical gears. The load concentration factor Kc is same for both gear types.
Design of Power
Transmission Devices 11.5 LOAD FACTORS
Design load factor, K was:introduced in the consideration of design equations as product
of load concentration factor, Kc and dynamic loadfactor, Kd.
Kc arises because the pressure between teeth when contact is established is not uniform
along the face width. The non-uniformly of contact pressure arises due to deformation of
tooth and shaft. The tooth deforms due to torque and also due to bending of shaft on
which gear is mounted. The ratio of maximum pressure to mean pressure is defined as Kc.
It represents the fact that force intensity at certain point on the tooth face will be higher
than at any other point. This higher intensity is more likely to cause greater damage,
hence must be used in calculation.
It becomes clear from the definition that shafts which are more likely to deform will
b
result in higher Kc value. Further the teeth that are longer (- ratio large) will also
dP
require higher value of Kc. So rigid shafts will cause smaller Kc while flexible shafts will
result in large Kc. If gear is placed symmetrically between bearings and close to bearings,
Kc will be small. Kc will be same for straight tooth and helical spur gears.
The dynamic load factor, Kd, mainly arises due to impact that occurs between teeth at the
beginning of contact. The inaccuracy in gear cutting causes the first point of contact not
to lie exactly on line of action. Moreover, the deformation on teeth immediately after
loading may cause point of contact to shift from line of action. It may be understood here
that the elastic deformation of teeth has opposite effects on pinion and wheel. It reduces
circular pitch on driving wheel while increases circular pitch on driven wheel. This
causes hammering of the particular tooth and acceleration on driven wheel. Such
hammering conditions, resulting in load enhancement will arise when the tip of the
driven wheel is making contact with dedendum portion of the driving pinion or when the
tip of the driving pinion is breaking contact with the dedendum of the driven wheel.
The value of factor Kd will naturally depend upon degree of accuracy of manufacture, the
velocity with which point of contact moves in or out and on hardness of the tooth
surface. The Kd will increase with increasing peripheral velocity for same hardness and
will reduce with increasing hardness for same velocity. The factor Kd will reduce with
increasing accuracy. Degree of accuracy is described by numbers 6 , 7 , 8 and 9. 6 is the
highest degree of accuracy corresponding to gear teeth which are shaved and ground.
Such gears are used with peripheral velocity in higher range (from 3 m/s to 12 m/s).
Hobbed and shaped gear teeth have accuracy corresponding to 7 and 8. Degree of
accuracy of 9 is obtained in gear teeth which are cut or milled and not generated.
The American Gear Manufacturers Association (AGMA) recommends following formula
for Kd.
For degree of accuracy 6 (teeth shaved and ground)

For degree of accuracy 7 and 8 (teeth hobbed or shaped)

For degree of accuracy of 9 (teeth cut or milled)

Peripheral velocity, v, is in d s .
The AGMA formulae for Kd do not consider hardness. Following tables may be used to
find Kd for straight tooth spur gears and helical gears.
I Table 11.1 : Dynamic Load Factor for Straight Tooth Spur Gears Helical, Bevel and
Worm Gears
Peripheral Velocity (mls)

9 5350 1.10 1.45

>350 1.10 1.45

Table 11.2 :Dynamic Load Factor for Helical Gears

b
Table 1 1.3 describes load concentration factor K, against v p = -.
dP

Table 11.3 :Load Concentration Factor Kc for Spur Gears

Near Toothed

From above description and tables it becomes clear that without knowledge of pitch
circle diameters of gears Kc and K d cannot be found (peripheral velocity will require
PCD). Therefore, the design equations developed cannot make use of these factors. The
solution is to assume Kcx KA= K = 1.5 and then determine pitch circle diameter and
Design of Power peripheral velocity. Then find v, and corresponding value of Kc fi-om Table 1 1.3 and
Transmission Devices value of Kd from Tables 11.1 or 1 1.2, respectively for straight tooth and helical spur
gears. Thereafter the product of Kc and Kd is checked to be less than 1.5 or equal to 1.5. If
this product turns out to be greater than 1.5 then module is increased to next step and
'
calculations redone to find the product of Kc and Kd. The procedure may be repeated until
we obtain K l 1.5.
The AGMA procedure of design starts from assumption of suitable value of module.
Such values can be selected from experience. Then bending stress is calculated with Kd
alone. The factor Kc is taken care of by limiting face width as
9 . 4 m < b < 15.7m
The calculated bending stress must be less than permissible stress of Eq. (1 1.13). This
takes care of fatigue loading. If calculated stress comes out to be greater than permissible
bending stress then the value of module is increased and calculation is repeated to find
fresh value of stress. If o < 06 then design is checked for surface stress.
Example 11.1
A 20 tooth pinion is required to transmit 20 kW of power to a 100 tooth gear. The
pinion and gear are held in a rigid housing with bearings arranged symmetrically
near them. The pinion is driven by an electric motor through a coupling at
950 rpm. Choose a steel which can be surface hardened to 350 BHN and assume
width to centre distance ratio of 0.6 and a factor of safety of 1.6 for surface stress.
Design straight tooth spur gear and helical gears of 30" helix assuming total design
load factor of 1.5 for straight tooth gear and 1.4 for helical gear. Also assume
pressure angle of 20" of straight tooth spur gear and in the plane normal to teeth for
helical gear.
Solution
Straight Tooth Spur Gear
Use centre distance formula

100
Substitute i = -= 5, K = 1.5, H = 20 kW, N j = 950 rpm, = 0.6
20

Using nearest standard value m, = 3.5 mm = 3.5 x m

b, = 0.6 Al = 0.6 x 210 = 126 mm . . . (ii)

(iii)
 Clieckfbt. Bellding Stress Helical, Bevel and
Worm Gears

0.7 o,
= - , o, = 3.3 BHN = 3.3 x 350 = 1155 MPa
K, x n

For calculating bending stress use

1.23 3.38
Y, =0.154--+- for pinion
20 202

= 62 193 x 1 o3 Pa = 62.2 MPa

which is much smaller than o h = 1 155 MPa.
Helical Gear
Use Eq. (1 1.8) for centre distance
- --I

Use K = 1.4, and all other values same as in case of straight tooth spur gear
1

2A2 cos P
.. m, =
Z, (1 + i)

-
- 2 x 174.2 x cos 30
= 2.9 x 0.866 = 2.51 1 mm
20 (1 + 5 )
Next higher value of m, is chosen as 2.75 mm or 2.75 x 1 o - m~

. . . (iv)
Dcsigtl of Power . . . (v)
Transmission Devices
. . . (vi)

or Y2=0.1176
The bending stress in tooth is calculated from Eq. (1 1.I 1)

or o=45x10"a or 45MPa
a is much less than a b= 1155 MPa.
We will compare the two solutions for H = 20 kW.
Dimensions of straight tooth and helical gear for transmitting same power,
same material and hardness.

Helical
Note all dimensions for helical gear are smaller than corresponding values
for straight tooth spur gear. The working bending stress is also less.
SAQ 1
(a) Show forces acting on a tooth of helical spur gear and write their
magnitudes in terms of power transmitted (kW).
Explain factors Kc and Kd.
Define normal and transverse modules and give relation between them.
A closed helical gear drive has been designed to transmit 7 kW of power.
Following are details of gears :
Material of pinion and gear - carbon steel heat treated to a, = 620 MPa
RPM of pinion, N, = 950

Face width of pinion and gear, b = 70 mm

Number of teeth, Z, = 35, Z, = 1 12
Normal module, m,, = 3 mm
Angle of helix, /3 = 16" 30'
Gears are normalised.
Calculate working stresses on surface and in bending and check if design is
safe.
 Helical, Bevel and
11.6 BEVEL GEARS Worm Gears

Bevel gears are used to transmit power between two shafts that are coplanar but inclined
to each other. The gears are formed by cutting teeth along the elements of frustum of a
cone. Though it is not necessary, yet it is a practice that shaft angle between bevel gears
is 90". Figure 1 1.2 describes various terms used for bevel gears.
Bevel frictional drives in which conical surfaces are pressed against each other can
transmit power like cylindrical surfaces. The conical surfaces transmitting same velocity
ratio as the bevel gears are called pitch cones. The apices of pitch cones are located at the
point of intersection of the shaA axes. The teeth cut on conical surface will diminish in
dimensions (i.e. both thickness and depth) towards the apices. This can be seen in
Fieure 1 1.2.

(a) A Pair of Bevel Gears

Crown

@) Nomenclature of Bevel Gears

Figure 11.2
As in case of spur gears, the profiles of teeth of bevel gears are also involute. However,
all the points of the conjugate sections of profile would lie on the spherical surface for
which pitch apex point (the point at which axes of the pinion and bevel gear intersect) is
the centre. It is difficult to develop the involute profile of bevel gear since the spherical
surface cannot be developed into a plane. Therefore, the involute profile of the bevel
gears is plotted, to some degree of approximation, on pitch circle of radius equal to the
back cone distance of radius as shown in Figure I 1.2(b). From this figure 'it is seen that
the elements of back cone are perpendicular to the elements of pitch cone.
i
Design of Power The module measured at the crown of the tooth (Figure 1 1.2(b)) is called maximum
Transmission Devices module, m,,. The module in the middle of the tooth is known as mean module, m,. It can
be shown that
b
m,, = m, + - sin yr
z
where y~ is the pitch angle of the bevel gear. y, and vWare shown as pitch angles of
pinion and gear respectively in Figure 11.2(b). Like other gears the pinion and gear in
bevel gear pair are identified by pitch diameters dp and dwfor pinion and gear
respectively. It is seen from Figure 11.2(b) that pitch diameters are measured on larger
side of tooth (i.e. outside of the tooth-circle). The mean pitch diameters, shown as d, and I

d, in Figure 11.2(b) correspond to the circle passing through the middle of the face width. i
The geometrical relationship among face width, 6 ; pitch diameter of gear, dw;cone
distance L and mean pitch diameter, d,,,, is illustrated in Figure 11.3. From this figure
0.5b
d,, = dw - -dw
L

Then

Dividing Eq. (1 1.18) by number of teeth Z,",

I

.I
Ln.
0 I
.I
0 .

Pitch radius dwl2

Mean pitch radius

Figure 11.3 :Relationship d o n g Face Width, Cone Distance, Pitch Radii and
Mean Pitch Radius of Bevel Gear

The mean module m, and maximum module m,, have already been defined. The
equivalent spur gear of the bevel gear is seen in Figure 11.2(b). The pitch radius of this
equivalent spur gear is equal to back cone distance and marked as h.
2
Similar
equivalent pitch diameter of pinion will be denoted by d,,. From Figure 1 1.2(b) it can be
seen that

and dpe = -
d~
cos W
Divide first of the above by the second equation
 i Helical. Bevel :111tl
ie = i t a n y ~ , =- Worm Gears
tan w,
Since ~ ~ + ~ ~ = 9 o ~

From Figure 1 1.3

. .2
Hence 1, =1

Again from Figure 1 1.2(b)

Also from Eq. (1 1.20) the equivalent centre distance or centre distance between
equivalent spur gear pair will be given by

dpe 1
But - is the inverse of equivalent velocity ratio, i.e. - which from Eq. (1 I .21) is
d we 1,
1
equal to T5-.
I

Hence . . . (i)

From Figure 1 1.2(b)

d w = L sin y ~ ,
-
2

Hence dwe -
- - L tan y, = iL (from Eq. (1 1.20))
2

Using this value of in Eq. (i)

2

11.7 FORCES IN BEVEL GEAR

The driving force P on a bevel gear will create the axial and radial force components. In
fact the actual forces on the bevel gears are distributed in three directions which are
mutually perpendicular. For convenience a bevel gear may be placed in coordinate space
of axes x, y and z as shown in Figure 1 1.4. The contact between the teeth generates the
normal reaction, P,,, between surfaces of-contact. With pressure angle a, the normal
reaction, P,,, is resolved into a tangential or driving force P and a force T which is
perpendicular to the conical surface as seen in Figure 11.4. The force T is resolved into
P,, a radial force component and force Pa, an axial force component.
 Dcsign ul' Power
.Transmission Devices

I
Figure 11.4 : A Bevel Pinion and earShowing the Forces Acting on Teeth in Contact. The Figure
also Shows Modification in d, and d , that they are Measured at Mid Point ofthe Tooth

From Figure 1 1.4

P = Pn cos a
P
or Pn =- . . . (i)
cos a
P being driving force is obtained from power transmitted, which will be denoted
by H (kW).
T = Pn sin a = P tan a . . . (ii)
The force T is resolved into axial and radial components.
P, = T cos y~ = P tan a cos \y . . . (1 1.24)
P, = T sin y~ = P tan a sin y~ . . . (1 1.25)
, y~ in above expression could be vpor v,, for pinion or gear respectively.
Important point to be noted in deriving above expressions is that the forces P, Paand Pr
are assumed to be acting at the mid point of the face width of the tooth, whereas the point
where the maximum values of these forces occur lies between the mid point and the large
end of the tooth. At the mid point the tooth profile coincides with the involute profile of
spur gear of the equivalent pitch diameter, considered in the last section.
It must be understood here that the force component P drives the gear while the
components Pa and Pr are transmitted to shaft. As such forces Paand P, will be used for
design of the shaft and selection of the bearings in addition to P. The design of the gear
either for contact stress or bending stress will be based upon the normal force P, as in
case of straight tooth spur gear or helical gear.
It may also be seen from Figure 11.4 that the radial fore on driven shaft (P,,) is equal to
axial force on driving shaft, but two are opposite in direction and vice-versa. Hence,
P, = - PaP . . . (1 1.26)
Ew=-P,
The driving force P can be calculated from Eq. (10.1 0) for transmission of H (kW) of
power if mean diameter dm, of dPmis substituted for d.
 Helical, Bevel and
11.8 SURFACE STRENGTH OF TOOTH IN Worm Gears
BEVEL GEAR
At the outset it must be understood well that the forces in a bevel gear are taken to be
acting at the mid point of the face width as mentioned in last section. The diameter of
bevel gear at that point has already been defined as mean diameter and represented by d,,.
It is recaIled that equivalent centre distance, A,, as given by Eq. (1 1.23) was calculated on
the basis of the understanding that equivalent spur gear tooth profile was at the bigger
end of the tooth. Now it is taken at the mid point of the tooth. At this point the cone

( I:
distance may be seen to have changed to L - - from L (Figure 1.4). Hence, the

Eq. (1 1.23) is modified by replacing L by L

used in further calculations, i.e.

( --
:1 ,and this modified equation will be

The design of a bevel gear is based upon the assumption that the driving force P in the
equivalent spur gear of equivalent diameter is same as the driving force in actual bevel
gear of given mean diameter when face width of the equivalent spur gear is 85% of actual
bevel gear face width and the two are rotating with the same speed.
Let H = Power transmitted in kW by bevel gear,
o = Angular speed of bevel gear or equivalent spur gear. It will be o, and owfor
pinion or gear,
dl,,= Mean diameter of the bevel gear. It will be d,,, or d,, for pinion or gear,
d, = Equivalent diameter of the spur gear. It will be d,, or d,, for pinion or gear,
and
H, = Power transmitted in kW by equivalent spur gear.

Then l 0 0 0 H = P -dm
a
2

and

Hence,

From Figure 1 1.4 it is seen that

However,

Hence, H,=H,/~~+I

i2 + I
or
Design of Power The maximum surface stress induced in the tooth of a spur gear is given by Eq. (10.25).
Transmission Devices The same equation can be used to calculate the surface stress in the tooth of a bevel gear
provided the quantities are replaced in the following manner,

Hence, omax =

The design load factor K = Kc x Kd has also been introduced. Substituting for
A, (Eq. (1 1.27)), i, (Eq. (1 1.21)), Hp (Eq. (1 1.28)) and be = 0.85 b.

Here L is in ma and o, in MPa.

L
The ratio v L= - varies between 2.8 and 5 for velocity ratio variation from 1 to 6. The
b
factor Kc and Kd are chosen from Tables 1 1.1 and 11.3. The peripheral velocity is
calculated for mean radius. The permissible value of contact stress, [oc]is selected from
Table 10.10.

11.9 BEAM STRENGTH

OF BEVEL GEAR TOOTH
It is firstly assumed that the strength of bevel gear tooth in the middle of face width
against bending is same as that of equivalent spur gear. Eq. (1 0.13) will be used to
express bending stress o, at the root of the tooth, i

In the above equation

H will be replaced by H , =
1
d z
m will be replaced by m,
 Helical, Bevel and
dPnl
d will be replaced by dpe = -----
COSW,
-
-
2, ms
cosyl,
- Worm G e a r s

b will be replaced by m, W,
where W, is a factor which varies between 8 and 10.

19100 K H j Z c o s W p
Hence, oh =
n cos 20 i Np 2, m: W, Y

It can be shown that cos v p = - l

,/z1-

Hence,

The permissible stress obis in Pa and in, in m. The form factor, Y, is obtained
corresponding to Z,.
i Example 11.2
An open bevel gear drive is required to transmit 3.5 kW of power. The pinion
having 18 teeth and made in steel rotates at 200 rpm. The gear made in C.1 rotates
I
at - of the speed of pinion. The ultimate tensile strengths of pinion and gear
4
materials are respectively 480 MPa and 230 MPa. Assume total design load factor
K = 1.5, W L = 4 and W, = 8. Calculate mean pitch diameters, pitch diameters, face
width, mean module and maximum module of the pinion and gear. Also calculate
the driving force, radial force and axial force on the pinion and gear.
Solution
For open drive the design will be based on bending strength. Eq. (1 1.30) will, thus
be used. However, this equation will be applied to either pinion or gear, depending
upon which one is weaker. The comparative strength will be determined by
comparing the product Y oband the one for which this product is smaller will be
regarded as weaker.
I The permissible stresses are calculated from
0.7 o,
Steel ob =-
n Ke
1.4 x 0.4 o,
and C.1- ob =
n Ke
From Table 10.15, for uniformly hardened steel
n = 1.8, K,= 1.2
From the same table for C.1 which is untreated,
n = 2.5, K, = 1.2
0.7 x 480
.. o, (steel) = = 155.6 MPa
1.8 x 1.2
1.4 x 0.4 x 230 = 43 Mpa
and ob ((2.1) =
2.5 x 1.2
Design of Power 1.23 3.38
Transmission Devices Tooth from factor, Y = 0.154 - -+ -
z z2
For pinion, Y, =0.154
3.38
--1.23 - +

= 0.096
18 1 8 ~

For C.1,

.. Yp crb (steel) = 0.096 x 155.6 = 14.9

Yw ob (C.1) = 0.1376 x 43 = 6
Hence, design will be based on wheel. Use Eq. (1 1.3)
- -I

The maximum module at the bigger end of the tooth corresponds to pitch diameter.
Use Eq. (11.19)

5.8
.. m,, = -= 6.63 mm . . . (i)
0.875
The standard module next higher than 6.68 is 7.0 mm.
:. Pitch circle diatneter, dw= 7 x 72 = 504 mm . . . (ii)
Pinion pitch circle diameter, d,, =7 x 18 = 126 mm . . . (iii)
Since, i=tanyw=4

y w= tan,' = 76'

Cone distance from Eq. (1 1.22)

L =L = = 259.75 mm . . . (iv)
2 2
L 259 75
Face width b = -= -- = 65 mm
WL 4 . . . (v)
The mean diameters of pinion and gear from Eqs. (1 1.18) and (1 1.19)

. . . (vi)

. . . (vii)
 The driving force fro111Eq. (1 1.3) Helical, Bevel and
Worm Gears
19100 H - 19100x 3.5 = 3032 N
e v = - . . . (viii)
N , d,,,, 50 x 44 1 x lo-'

evr= P,,, 'tan a sin y~,, (Eq. (1 1.25))

= 3032 x tan 20 x sin 76

= 3032 x 0.364 x 0.97 = 1070.5 N . . . (ix)

P,,,= P,,, tan a cos y~,, (Eq. (1 1.24))

= 3032 x 0.364 x 0.242 = 267 N . . . (x)
Note pp = p,.,ppr = pWO,ppo= pWr . . . (xi)

I (a) Show forces acting on bevel gear.

On a sketch show face width, cone distance, pitch radius and mean pitch
(b)
radius. Give relationships between mean pitch diameter and pitch diameter,
mean module and maximum module.

(c) In a closed bevel gear drive pinion with 29 teeth rotates at 1000 rpm and
transmits 25 kW of power to gear of I00 teeth. Both pinion and gear are
made in medium carbon steel which is normalised and hardened to
350 BHN. The design load factor is 1.5 for gears of pressure angle of 20".
~ J=L 5. Determine

(i) the cone distance L,

(ii) face width, b,
(iii) mean pitch diameters, and
(iv) module of teeth.

11.10 WORM AND WORM GEARS

Transmission of power and motion between two intersecting shafts is a common
occurrence in industry. If these shafts lie in the same plane, then bevel gears provide the
best solution. However, such shafts may lie in two parallel planes and if angle between
them is 90" then they may be connected with worm and worm wheel.
Worm and worm wheel drive are used between shafts and cross in the space at right
angle and offer many advantages.
The worm and worm wheel drives are quiet in operation. Very high speed ratios can be
transmitted by these drives while occupying very small volume. Worm and worm gear
drives have smallest weight and are costlier than only V-belt and flat belt drives. The
worm gear drives can have large velocity ratios often varying between 5 and 500.
However, in most mechanical engineering applications where powei transmission is
Design of Power foremost requirement the velocity ratios between 10 and 80 are common. A single stage
Transmission Devices worm wheel drive having a velocity ratio in the vicinity of 80 will be much smaller than
corresponding spur wheel drive (or spur-bevel combination) which may have as many as
three stages. One important advantage of worm gear drives is that they are irreversible.
What it means is that if power is applied on the shaft of the worm wheel the worm cannot
be rotated. This property of irreversibility makes worm gear drive a ready choice in load
hoisting devices where load suspended from cable wound on drum keyed to the worm
gear shaft will stay in that position without application of brake.
The worm gear drive has a few disadvantages, particularly compared to spur gear drives.
The worm and wheel have some sliding between them which results in heating and
reduction of efficiency. Because of these reasons the power transmission capacity of
worm gear drive is limited to 75 kW.

11.11 GEOMETRY AND VELOCITY RATIO

Figures 1 1.15(a) and (b) illustrates worm and worm wheel respectively in actual state and
schematically. The worm in worm and worm gear drive is same as screw in screw and
nut pair described in Unit 5. A screw and nut pair appears in Figure 11.6(a). It is
understood from earlier description that if the nut is restricted from rotating, it will move
axially when the screw is rotated about axis I-I. If only a segment of the screw, having a
length L is considered and is curved into a circle of diameter D as shown in
Figure 1 1.6(b) then a worm and worm wheel combination will be obtained. It can be
easily seen that the worm gear obtained from coiling of nut segment will still have the
contact with thread of the worm. If the worm is rotated about axis 1-1, the segment will
rotate about axis 11 which is perpendicular to the plane of the paper. It may however, be
remembered that the screw and nut in this example have trapezoidal section whereas
worm in worm and gear drive has profile of involute.

(a) Worm and Worm Gear Combination

Worm dl2 -1

, (b) Schematic of Worm and Worm Gear

Figure 11.5
 Helical, Bevel and
Worm Gears

(a) A Screw and Nut Pair

(b) The Nut Segment of (a) bent into a Circle of Diameter D

Figure 11.6
The worm is also characterised by pitch, denoted by p as in case of screw. The pitch is
defined as the distance between two adjacent threads and it is the distance moved by nut
when restricted from rotation and screw rotates through one rotation. If multistart thread
is made on the screw or worm then during one rotation the distance moved by nut will be
number of starts times the pitch.
Let us denote pitch by p and number of starts by 21.
Then the distance moved by nut during one rotation of screw

The distance zl p is called lead of the screw or worm and denoted by S, so that

Now if the nut has been converted into worm gear then it will move about its axis
through an angle corresponding to an arc length of S whereas total circumferencial length
is x D.
The angle through which worm gear rotates,

Using Eq. (1 1.32) in Eq. (i)

. . . (ii)

During this motion of worm gear the worm has rotated through one rotation or through
an angle of 2x. If the speed of worm and worm wheel are respectively N I and N2 rpm,
then
N, a 2x

4 -- -
Hence, i = velocity ratio = - xD . . . (iii)
N2 21 P
The worm and worm gear moving in contact will have the relationship that
Pitch of screw = Circular pitch of the wheel
The circular pitch of the wheel is defined as the circumference of the wheel divided by
number of teeth on the wheel. Hence, p in (iii) can also be written as
Design of Power
Transmission Devices

where Z2 is the number of teeth on the worm gear.

Hence, (ii) is modified to

i.e. velocity ratio of worm and worm wheel is the ratio of number of teeth on the wheel
and number of starts on the worm. Thus a high velocity ratio can be obtained by having a
worm of single start (z, = 1) for same number of teeth on worm gear.
The shape of the worm threads in axial section is shown in Figure 1 1.7. This section is
same as profile of a rack and the included angle at the top is often 28 = 40". This kind of
worm whose section in axial plane is trapezium is called Archimedean screw. The pitch
and axial module are related as
p=xm . . . (iv)
Using Eq. (1 1.32)

Figure 11.7 :The Worm Thread in Axial Section

The pitch diameter of worm, d, is related with the axial module through following
equation

Here q represents the number of modulus in the pitch diameter of the worm, q is
normally chosen between 8 and 13.
Various dimensions of worm and worm wheel are illustrated in Figure 11.8. The
dimensions and nomenclature will be described subsequently. The lead of the thread in a
screw was defined in Unit 5 and for single start screw (i.e. z l = 1) the helix angle is given
by Eq. (5.1). By the same definition the lead angle

a = tan - 1 S
xd
where d is the pitch diameter of the worm.
Using Eq. (1 1.32) in Eq. (v)

a = tan - I
xd
Using Eq. (iv) and Eq. (1 1,35) in Eq. (vi)

a = tan- 1 -
21

4
,. The lead angle in worm is same as the helix angle in the screws. In case of worms the Helical, Bevel and
Worm Gears
helix angle is complementary of lead angle. If helix angle is denoted by h, then

a + h = 90' . . . (vii)
This is shown in Figure 1 1.8.
Won
Pitch cylinder

Helix angle

Figure 11.8 :Worm and Worm Wheel Showing Various Dimensions

The centre distance between worm and wheel is denoted by A . With reference to
Figure 1 1.8

(viii)

Where d is the pitch diameter of worm and D is the pitch diameter of worm wheel. D,
and d, are the addendum diameters while Dd and dd are the dedendum diameters of wheel
and worm respectively. Do is the outside diameter of worm and

since the wheel rim envelops the worm. The degree of envelopment is defined by the face
angle 2y.
The face width of the worm is denoted by b.
The various dimensions are calculated by using following equations.

Radial clearance = 0.2 m

Using Eq. (1 1.35) and fourth of Eq. (1 1.37) in Eq. (viii)

Design of Power I

Transmission Devices 11.12 FORCES IN WORM AND WORM GEAR

Determination of forces becomes important in calculating stresses in thread and teeth.
The forces are borne by the shaft of worm wheel and the worm itself. The worm is
supported in bearings and acts as shaft, so it will be subjected to torque and bending
moment. The force that drives the wheel is axially acting on worm but not along axis but
parallel to axis as can be seen in Figure 1 1.9. This force is replaced by an axial force and
a moment which will tend to bend the worm. See Figure 1 1.9 for various forces and
Figure 1 1.10 for their relationship. The axial force on worm causes torque in the same
way as it does in screw.
I

Figure 11.9 : Forces on Worm and Worm Wheel

Figure 11.10 : Relationship among Forces on Worm and Worm Wheel

Eq. (5.5) correlates the torque and the axial force. Using this equation for worm by
replacing
P I L by M,= the torque on worm
Wby P = axial force on worm
dd by d = pitch diameter of worm
Here we denote axial force by P and pitch diameter of worm by d. The torque on the
worm is denoted by M,.
a and $ are respectively the lead and friction angles.
d
Hence, MI = P - 2t a n ( a + $ )

If the power transmitted is H kW at N Irpm.

Then
 19100 H 1 Helical, Bevel and
Hence, P= ,N Worm Gears
N, d tan ( a + 4)
where d is the diameter of worm in m.
The Eq. (I I .4l) thus gives the turning force on the wheel.
a, is the pressure angle of worm in the nomlal section cut by a plane perpendicular to the
thread. If the section is considered cut by a plane through the axis then pressure angle
will be a, (different than a,). Both angles a,, and a, are illustrated in Figure 11.10 from
which it appears that the normal force P,, produced on thread surface can be resolved into
two components, viz., T and R. R is the force which tends to separate worm and gear and
will cause bending of the shafts of worm and worm wheel. Apparently
T = 4, cos a, . . . (i)
R = P, sin a, . . . (ii)
The force T acts in the horizontal plane with reference to the vertical plane worm wheel
shown in elevation in Figure 1 1.9. The same force is shown in plane of worm in this
figure. The force T acts at an angle a (the lead angle) with the axis of the worm. T is
resolved into two components, viz, P , and Q, P is the driving force on wheel while being
parallel to axis of worm. Q is the driving force on worm while being parallel to axis of
d d
worm wheel. The torque on the worm will be Q - while P - will be a bending
2 2
D
moment on the worm shaft. Similarly Q - will be a bending moment on the shaft of the
2
worm gear. From Figures 1 1.9 and 1 1.10.
P = T c o s a = P, cos a cos a,

r
so that P, = . . . (iii)
cos a cos a,

Using Eq. (1 1.41) in Eq. (iii)

19100H c o t ( a + $ )
P, = . . . (1 1.42)
N , d cos a cos a,
Again from Figures 11.9 and 11.10
Q = P tan a . . . (iv)
Using Eq. (1 1.41) in Eq. (iv)
19100 H tan a
. . . (1 1.43)
= N, d tan ( a + 4)

Also from Eq. (1 1.41) and Eq. (ii)

19100 H tan a,
R= cot ( a + 4)
N, d cos a

From Figure 1 1.10 it can be seen that

19100 H
R = P tan a, tan a, cot ( a + 4)
N, d
Equating right hand sides of Eq. (1 1.44) and Eq. (v)
tan a,
tan a, = -
cos a
I>esigo uf Power Example 11.3
'Transmission Devices
An 80 mm pitch diameter worm rotating at 950 rpm transmits 4.5 kW of power.
The worm is supported in bearings which are 350 mm apart. Calculate maximum
bending moment, the bending stress and the shearing stress in the worm shaft.
Helix angle = 7", coefficient of friction between worm and gear = 0.078. The
pressure angle in the axial section, a, = 20".
Solution
H = 4.5 kW, NI = 950 rpm, d = 80 mm, a = 7", a, = 20°, p = 0.078
tan 4 = 0.078, 4 = tan-' 0.078 = 4.46' . . . (i)
From Eq. (1 1.49,

tan a, = cos a . tan a, = cos 7' . tan 20'

or tan a, = 0.9925 x 0.364 = 0.3612, a, = 19.86' . . . (ii)
tan ( a + 4) = tan (7 + 4.46) = 0.203 . . . (iii)
The axial force on worn,
19100 H
P = N from Eq. (1 1.41)
N p d tan ( a + 4)
Use NI = 950 rpm, d = 80 mm, H = 4.5 kW, tan ( a + 4) = 0.203

. . . (iv)

The driving force on worm is given by Eq. (1 1.43)

19100 H tan a
= N, d tan ( a + 4)
= P tan a =5571 tan 7 =684 N . . . (v)
Radial force on worm shaft, i

19100 H tan a,
R= from Eq. (1 1.44)
N, d tan ( a + 4)

= P tan a, = 5571 tan 20 = 2027 N . . . (vi)

P, Q and R are three faces acting upon the shaft of the worm in three
perpendicular directions. Figure 11.1 1 shows these forces schematically on shaft
supported in bearings 350 mm apart. P (horizontal) and R (vertical) act in vertical
plane passing through the axis of the worm while Q acts in horizontal plane. P and
d
Q act on the shaft at a distance of - form the axis. Thus, P will &use a bending
2
d
moment P - on shaft in vertical plane and an axial force. Q will cause a torque

Q,
2
d
and a transverse force Q on the shaft.

The reader must calculate the reactions on right and left hand supports by taking
moments about left and right hand supports respectively and ascertain the values
shown in Figure 11.11.
Rl P d
:. Maximum BM (at mid section) in vertical plane, M y = - + -
4 4
 Helical, Bevel and
Worm Gears

= (177.4 + 111.4) 10' = 288.8 x 10' Nmm . . . (vii)

Q1
Maximum BM (at mid section) in horizontal plane, M H = -
4

. . (viii)
The torque on the worm shaft,

. . . (ix)
The resultant BM at mid section,

or M = \/288.g2 + 59.g2 x lo3 = 295 x lo3 Nmm . . . (x)

Vertical Plane Horizontal Plane

Figure 11.11 :Forces on Shaft of Worm Shown Schematically

The area that resists bending stress due to M and shearing stress due to M,is the
core section of the worm whose diameter is the dedendum diameter of worm. This
is found from second of Eq. (1 1.37),

tan a = -ZI
4
From Eq. (1 1.36) in which a = 7' and zl = 1.

1
.. tan 7' = 0.123 = -
4
so that q = 8.144
d
m =- from Eq. (1 1.35)
4

:. d d = worm dedendum diameter = d - 2.4 m = 80 - 23.6 = 56.4 mm ... (xi)

Core area, = 2
A, = - =
dd = 7 (56.4)2 = 2498.32 mm2
4
P 5571
. Compressive stress, a, = - = = 2.23 ~ / m m ~ . . . (xii)
I A, 2498.32
Design of Power 3 2 M 32x295x103
Transmission Devices Bending stress, ob = -- = 16.75 N/mm2 . . . (xiii)
x d: x (56.41~
16M 1 6 x 1 3 . 7 x 1 0 ' = ~ ~ ~ ~ ~ ~ ~ ~
Shearing stress, T= = (xiv)
nd x (56.4)3
o(,and o, are direct stresses, hence, they may be added. The tensile stress

The state of stress with tensile stress is shown in Figure 1 1.12.

Figure 11.12

11.13 DESIGNING OF WORM WHEEL

The modes of failure discussed in respect of gears are applicable to worm and worm
wheel also. However, since sliding between worm andwheel occurs the possibility of
seizure is much higher in this case. Particularly if speed is high the oil tends to be
squeezed out from contact and seizure may occur. To reduce sliding friction the worm
wheels are often made in softer material like bronze while the worm is made in steel.
Softer material has greater tendency to stick to the harder material. Good finish of worm
and the combination of materials to have lowest coefficient of friction are used to reduce
seizure occurrence. As in other toothed gears varying load causes pitting of worm wheel
teeth surfaces and if seizure is avoided then pitting will finally cause the failure of gear.
The wear of both worni and worm wheel is a life long process particularly if the drive is
often stopped and started. The lubricating oil must be kept cleaned because dirty oil
causes wear.
Seizure is difficult to analyse and hence no formula is developed for design based on
seizure. The compressive surface stress is calculated form Hertz equation. The worm is
assumed to be made in steel for which El = 2.1 x lo5 N/mm2 and worm wheel is made
in bronze for which E2 = 0.9 x 10' N/mm2 so that rationalised modulus of elasticity
E = 1.26 x 10' ~ / m m We ~ . will not go into details of developing equation for surface
stress, instead we will directly use the equations for surface stress and bending stress.
These equations are described below.

The design equation is

a, is in MPa.
The n~odule,nr, can be calculated from Helical, Bevel and
Worm Gears

The bending stress is given by

The design equation is

In the above equations all quantities hdve been defined earlier. However, we repeat them
here for emphasis and you must note the units in which the quantities will go into
equations.
K = Design load factdr, product of Kc and Kd,
H2 = Power transmitted by worm wheel. (Note this power will be less than that at
worm shaft because of friction between worm thread and teeth of worm
gear), kW,
N2 = rpm of worm wheel,
Z2 = Number of teeth on worm wheel,
d
q = Number of modules in worm pitch diameter, i.e. q = - ,
m
D+d
A = Centre distance between worm and worm wheel, i.e. A = -m ,
2
a, = Surface stress in worm wheel tooth and worn1 thread, Pa,
ob= Bending stress in worm wheel tooth, Pa,
Y = Form factor for worm wheel, and
m = Axial module, m.
As in case of other gears, K is assumed to be 1.5. Yet note that Kd in case of worm and
worn1 wheel is much less because

(a) the contact between thread of worm and teeth of worm wheel never breaks,
and

(b) the peripheral velocity in this case is much less.

Kd varies between 1 and 1.1 for peripheral velocity less than 3 mls. For peripheral
velocity greater than 3 m/s, Kd varies from 1.1 to 1.2. Kc can be calculated but we leave
this calculation for complex nature. It is not much higher. The product K = Kc x Kd is less
than 1.5 in most cases.
Worm and worm wheel drives normally are made with worm in steel and worm wheel in
bronze but cast iron is also sometimes used as worm wheel material. Note that
Eqs. (1 1.46) and (I I .47) are applicable only to steel-bronze combination as it uses
modulii of elasticity. However, Eqs. (1 1.49) and (1 1SO) are applicable to bronze and cast

I
iron both.
The permissible values of oband o, are given in Table 1 1.4.
Design of Power Table 11.4 :Permissible Surface Stress (a,) and Bending Stress (ab)
Transmission Devices
Material Condition all Permissible Stress a, and ab
(MPa) (MPa)
a, with Worm Reversed
Surface Hardness Bending
1 I Rc<45 I Rc>45
1 stress, a b * I
Tin Bronze Loam cast 180 145 145 36
Chill cast 250 200 243 52
Centrifugal cast 240 230 278 57

1 Tin Free
Bronze
Cast Iron
1 Loam cast
Chill cast
400
1 5 0 0 1
-
-
-
1 - 1 -

-
80
88 1
Loam cast 120 26
150 - - 30
180 - - 34
-

* Tabulated value is for reversed bending. In case of worm and worm wheel drive
the stress is pulsating. Hence, tabulated values are multiplied by 1.3, 1.2 and
1.4, respectively for 1 , 2 and 3.
Example 1 1.4
A worm and worm wheel drive is required to transmit 4.5 kW of power with
velocity ratio of 35. 'The driving shaft rotates at 950 rpm. The worm is made in
medium carbon steel which is heat treated to 50 R,. The wheel rim is made in tin
bronze with o,, = 250 MPa. Design worm wheel for zl = 1.
Solution

From Table 1 1.4, o, = 250 MPa is for tin bronze chill cast for which o, is read as
243 MPa for worm hardness of 50 R, > 45 R,. Also obfor reversed bending is read
as 52 MPa which will be 1.3 x 52 = 67.6 MP for pulsating bending.
Let us design worm gear for surface strength by using Eq. (1 1.47). We substitute
o, = 243 MPa, Hz= 4.5 kW, Z2= 35, K = 1.5, N2 = 27.143. Note that o is in MPa
in Eq. (1 1.47). Let us choose q = 10 (it can be chosen between 8 and 13).

Using Eq. (1 1.39)

m=-
2A = -2 x 2 0 2 = 8.97 say 9
q + Z 2 10+35
Hence, A is modified as

. . (i)
 Then from Eq. (1 1.35), tlelical, Revel and
Worm Gears
. . . (ii)
The pitch diameter of wheel from

z
Helix angle a = tan-' from Eq. (1 1.36)
4

1
a = tan-' - = 5.71' . . . (iv)
10
For checking bending stress first calculate Y

. . . (iv)

or ob = 59.4 MPa

The permissible bending stress is 67.6 MPa. Hence, the gear is safe.
I
I
SAQ 3
(a) Discuss Kcand Kdfor worm and worm gear combination.

(b) What materials would you recommend for worm and worm wheel?

(c) Solve Example 1 1.2 of Section 1.8 for zl = 2 and q = 10, zl = 2 and q = 8.

(d) A worm and worm wheel drive with a velocity ratio of 25 transmits 10 kW
of power. The worm rotates at 1250 rpm. The worm wheel is made in tin
bronze, cast centrifugally to have following properties. o,= 3000 MPa,
06 = 81 MPa, o,= 279 MPa. Assume double start worm, and number of
module in worm pitch diameter, q = 10. Apply a factor of safety of 1.7 on
surface strength. Calculate centre distance, A , axial module, m, worm pitch
diameter, d, worm wheel pitch diameter, D and check if design is safe in
bending.
Design of Power
Transmission Devices 11.14 SUMMARY
Helical, bevel and worm gears have been considered for designing. Helical gear design IT
extended from previous unit. However, design load factor which is the product of load
concentration factor and dynamic load factor has been explained in detail. It is easier to
assume K = 1.5 at the initial stage and calculate dimensions of gear and then calculate
peripheral velocity and find Kc and Kd. The design will be acceptable if Kc x Kd is less
than 1.5. The bevel gear design formulae, like those for straight tooth and helical spur
gears have also been developed for surface strength (compressive) and against bending.
The permissible bending stress is consideration, fatigue strength reduction factor for
stress concentration and a factor of safety which depends upon material and heat
treatment. These factors have been tabulated. The ultimate surface strength which is
compressive is related to surface hardness like the ultimate tensile strength. A factor of
safety of 1.7 should be applied on surface strength calculated from hardness.
The geometrical difference between worm and worm wheel and other gears has been
discussed. The various loads that act upon worm and worm wheel have been calculated.
The worn1 is designed as shaft of diameter which is core diameter, dd. On the shaft the '
direct, bending and shearing stresses are considered. The worm gear is designed as other
gears.
The design of gear is made such that it is safe both under surface strength and against
bending. The load on gears is varying hence fatigue considerations are must. We can
calculate centre distance and then module from consideration of surface strength anld then
check if gear is safe under bending. Or we can calculate module from consideratiorl of
bending stress, then centre distance and check for surface stress. American Gear
Manufacturer's Association (AGMA) recommends to assume module and check against
both surface and bending strengths.

11.15 KEY WORDS

Bevel Gears : Bevel gears are used to connect two intersecting
shafts with any given speed ratio.
Pitch Cone : The pitch surface of a bevel gear in a gear pair is
called pitch cone.
Back Cone : It is an imaginary cone the elements of which are
perpendicular to the elements of the pit.ch cone at
the larger end of the tooth.
Length of the Worm : The length of the toothed part of the worm
measured parallel to the axis on the reference
cylinder.
Lead Angle : Lead angle is the angle between a tangent to the
pitch helix and the plane of rotation of the worm.

11.16 ANSWERS TO SAQs

SAQ 1
(d) From Eq. (1 1.10)

A =- m, Z p + ,Zw -
3
- . 3 5 + 1 1 2 = 230 mm . . . (i)
cos p ' 2 cos '
6 30' 2
 2n N p dp Helical, Bevel and
Peripheral speed v = -- Worm Gears
60 ' 2

. . . (iii)

Assume that bearings are arranged symmetrically near gears. Then from
Table 11.3 Kc for vP= 0.64 is found by interpolation between vP= 0.6 and
w,,= 0.8.
. . . (iv)

Using o,.= 3.3 BHN MPa

620
BHN = -= 187.8
3.3
which is less than 350.
From Table 11.2 for BHN < 350 and v between 3 and 8 m/s
K(,= 1.0
... K = Kc x Kd = 1.036 . . . (v)
Use Eq. (1 1.7),

in which i = 32, H = 7 kW, K = 1.036, Np= 950, A = 230 x

omax = 28.4 x lo6 ['4.2'3 '

950 x 3.2 x (230)~x 0.3 I!
x"036 " " lo9Pa = 197.6 MPa . . . (vi)

The surface strength = 2.6 BHN = 2.6 x 187.7 = 488.28 MPa working
surface stress in less than surface strength giving a factor of safety

. . (vii)
From Eq. ( I 1.1 1) bending stress in tooth
Design of Power 1.036 x 7
Transmission Devices . o = 4790.3 x- I pa
950 x 39.7 x 23.3 x (0.003)' 0.125
= 1 1552969.72 Pa = 1 I .5 MPa

Permissible bending stress,

0.7 x o, =
oh = 0.7 620 = 160.7 MPa
Ken 1.8x1.5
(K, = 1.8 and n = 1.5 found from Table 10.15)
160.7
:. Factor of safety in bending = -= 14
11.5
Design is safe.
SAQ 2
(c) Ultimate tensile strength,
o,, = 3.3 BHN = 3.3 x 350 = 1155 MPa
Surface strength,
o,,, = 2.6 BHN = 2.6 x 350 = 910 MPa
Permissible bending stress,

From Table 10.15 for forged, normalised arid hardened steel n = 1.5,
K, = 1.8.

Permissible surface strength,

o c = = 545 MPa
1.67
Velocity ratio of the drive
i=tanvw=5

:. y ~ , = t a n - ' 5 = 7 8 . 7 ~ , y ~ , 90-78.7=11.3°
, . . . (i)
We propose to design gears on surface strength and check its safety in
bending. Hence, use Eq. (1 1.30)

1.5 x 25
:. L = 10.9 x lo4 x 5 (25 + I)?
'[ 5 x 1000 (4.5)' (54q2 x 1 0 ' ~

= 278 x lo4 x lo-' [0.01 I] = 0.3058 m or 305.8 dm . . . (ii)

 The pitch diameter of wheel and cone distance are related (Figure 1 1.3) tlelical, Bevel and
Worm Gears
d
2= L sin W , = 305.8 sin 78.7' = 300
2
or d,, = 600 mm
The maximum module or module at the bigger end is calculated from
- d,
- 600
mrnax - --- = 6.00 mm . . . (iii)
z,, 100

which is standard.
:. d , = nz ,, Z p = 6.00 x 20 = 120 mm . . . (iv)

d,,, = d,
i I:1 - - = 6.00 1 - - = 540 mm
O f ,
. . . (v)

d,,,, = d
[ ] I-- =I20 I--
( Of::
=108mm . . . (vi)

. . . (vii)

The design is checked against bending stress through

Y for 20 teeth,

= 67.3 x lo6 Pa or 67.3 MPa

oh is less than 298 MPa, hence gear is safe in bending.

SAQ 3

(b) Follow Example 1 1.2 of Section 1.8 and find following

ZI q m (mm) A(mm) d(mm) D(mm) ub(MPa)

2 10 6.0 240 60 420 103.3
2 8 6.5 253.5 32 455 101.8
Note that in both cases bending stress is greater than permissible value of
67.2 MPa. Hence, these designs are not safe. You may increase m to say
7.0 mm and recalculate oh.If ohis safe then calculate other dimensions.
Design ol' Power 1250
Transmissio~~ Devices (d) Z2=izl=25x2=50,q=10,K=1.5,N2=-=50,H2=10kW
25

(3, =-278 = 163.5 MPa

1.7
Use Eq. (1 1.47)

2A 2x294
Axial module, m = -= -- 9.8 mm say 10 mm ...
q + Z 2 10+50

Hence, A = m (9 + 22) - 10 (10 + 50) = 300 mm . . . (ii)

2 2
First check for bending using Eq. (1 1.49)

7410 x 1.5 x 10
Ob = Pa = 34 MPa
10 x 50 x (0.01)~50 x 0.131
which is less than permissible bending stress of 8 1 MPa. Hence, safe.
d =rnq=lOxl0=100mm . . . (iii)
D = 2 A - d = 2 x 300- 100 = 500 mm . . . (iv)

FURTHER READING
Vallence and Doughtie (1943), Design of Machine Members, McGraw-Hill Company.
Movnin and Goldziker (1966), Machine Design, Mir Publishers.
Dobrovolsky, Zablonsky, Mak, Radchik, Erlikh (1966), Machine Design, Foreign
Language Publishing House, Moscow.
Norton (2000), Machine Design, Pearson Education.
Shigley (1986), Mechanical Engineering Design, McGraw-Hill Con~pany.
Abdul Mubeen (2005), Machine Design, Khanna Publishers.