KISSsoft 03/2013 Tutorial 16

Analyzing the Geometry of Cylindrical Worm Gears that have a double enveloping Worm Wheel

KISSsoft AG Rosengartenstrasse 4 8608 Bubikon Switzerland Tel: +41 55 254 20 50 Fax: +41 55 254 20 51 [email protected] www.KISSsoft.AG

Contents
1 Task ......................................................................................................................................................... 3 1.1 Task ................................................................................................................................................ 3 1.2 Starting the drive element of a worm gear with a globoid worm wheel. ......................................... 3 1.3 Input data in main screen ............................................................................................................... 4 1.4 Special features of worm gear teeth flank surfaces ........................................................................ 6 1.5 Input data for the gear pair ............................................................................................................. 6 1.6 Inputting tolerances ........................................................................................................................ 8 2 Strength calculation.................................................................................................................................. 9 2.1 Results of the rating and geometry calculation ............................................................................. 10

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1 Task
1.1 Task
To calculate a worm gear with center distance 100 mm. The worm has 2 teeth, and the worm wheel has 41 teeth. The axial/transverse module is 4. The pressure angle at the normal section is 20. The worm's facewidth is 60 mm. You should select a sensible facewidth for the worm wheel. The axis tolerance is js7. The worm's tooth thickness deviation in the normal section is between 0 and -0.04 mm. The tooth thickness deviation for the worm wheel is between -0.128 and -0.168. The external diameter of the worm is 44 -0.01 mm. The root diameter is 26.4 -0.110 mm. The effective tip clearance is to be 0.8 mm. The root radius factor is 0.2. The inside radius diameter is 134.4 mm. The tolerance for the external diameter of the worm wheel is between 0 and -0.01 and for the active root diameter it is between -0.360 and -0.473. The worm is to be manufactured with accuracy grade 6 as specified in DIN 3974. The worm wheel is to be manufactured with quality 7. The lead direction is to the right. The worm's flank form is ZI.

1.2 Starting the drive element of a worm gear with a globoid worm wheel.
You can call KISSsoft as soon as the software has been installed and activated. Usually you start the program by clicking "StartProgram FilesKISSsoft 03-2013KISSsoft". This opens the following KISSsoft user interface:

Figure 1.

Starting KISSsoft, initial window

In the Modules tree window, click the "Modules" tab to call the "Worms with enveloping worm wheels" calculation:

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Figure 2.

Call to the worm gear calculation

1.3 Input data in main screen

After you call the Worms with enveloping worm wheels, this input screen appears. To only perform a geometry calculation, disable the "Calculation -> Rating" option in the menu.

Figure 3.

Input screen for worms

Input values for the axial/transverse module, number of teeth, quality, and worm face width, in the "Basic data" tab. You must also input the center distance (1). The subsequent interim value is calculated because only the lead angle needs to be calculated. To do this, click the "Convert button" (2) and then click "Calculate" (3) to determine the lead angle. Finally, click Accept (4) to transfer this data to the main screen (see Figure 4).

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1 2

Figure 4.

Interim state with the Sizing lead angle input screen

Click the "Details" button to call the "Define details of geometry" sub-screen and then select the appropriate flank form ZI. You must also input the inside diameter of the worm gear as 134.4 mm.

Figure 5.

Interim status with "Define details of geometry" input screen

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1.4 Special features of worm gear teeth flank surfaces

The flank surfaces of a worm gear are defined in a different way from those in cylindrical gears.

Figure 6.

Calling the information graphic to describe wheel rim width b2R and wheel width b2H en

Then click the "Sizing"

button to calculate the facewidth.

Figure 7.

Calculated wheel rim width b2R

1.5 Input data for the gear pair

In the "Reference profile" tab, select "Own Input" as the predefined tool profile. Then click the appropriate Convert button to calculate the tip and the addendum and dedendum coefficients for the worm. When you click Accept, these values are transferred to the main screen.

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Figure 8.

Calculating the worm root or tip diameter

Input 0.2 as the root radius factor. The effective tip clearance is then used to determine the root or tip diameter for the worm wheel. The active root diameter is calculated from (center distance tip diameter of worm/2 - tip clearance)*2 =(100 - 44/2 0.8)*2= 154.4 mm. The tip diameter is calculated from (center distance active root diameter of worm/2 - tip clearance)*2=(100 26,4/2 0.8)*2= 172 mm. Once again, click the relevant "Convert" button to convert the dedendum and addendum coefficient at the worm wheel. Then click Accept to transfer the values to the main screen. Explanation: when you call the worm gear calculation, the system already provides predefined base settings. However, the default profile 1.25/ 0.38/ 1 ISO 53 A does not match what we want. The software already shows that it has calculated the tip diameter detailed above. The particular geometry of globoid worm gears also means you need to calculate the throat radius and the external diameter de2.

Figure 9.

Geometry of globoid worm gears

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In the "Basic data" tab, click the "Details" button to open the "Define details of geometry" sub-screen. Then click the Sizing button to run the required calculations for the throat radius rk and the external diameter de2. For more information see Figure 10.

Figure 10.

Calculating tip gorge radius rk and the external diameter

1.6 Inputting tolerances

In the "Tolerances" tab, select "Own Input" instead of using the predefined dimensions. Then input the tooth thickness allowance in accordance with the default values and then enter the tip diameter allowance.

Figure 11.

Inputting tooth thickness tolerance and tip diameter allowances

Then check the root diameter allowance and modify it if necessary. Now select the center distance tolerance.

Figure 12.

Center distance tolerance input

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The following changes must now be made so you can perform the strength calculation later on: facewidth of worm is 60 mm, increase the required facewidth of the worm wheel b2R to 31 mm and the external diameter de2 to 181.41 mm.

Figure 13.

Final inputs

These are the results of the calculation.

2 Strength calculation
The various different calculation methods are documented in the manual (Chapter 16). Please refer to the notes if you have any questions. To open the prepared example used in this tutorial, click "File Open" and select "WormGear 1 (DIN3996 Example 1)".

Figure 14.

Opening the example calculation

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2.1 Results of the rating and geometry calculation

KISSsoft-Entwicklungs-Version KISSsoft Release 03/2013 KISSsoft AG CH-8608 BUBIKON File Name : Description: Changed by: WormGear 1 (DIN3996 Example 1) KISSsoft example ho am: 04.03.2013

um: 16:08:10

WORMGEAR ANALYSIS Drawing or article number: Worm: 0.000.0 Gear: 0.000.0 Calculation method DIN 3996:2012 (Geometry: DIN 3975:2002) Geometry calculation from axial module ------- WORM---------------- WHEEL ---Power (kW) Worm driving Power (kW) Speed (1/min) Application factor Torque (Nm) Required service life Number of starts (1/h) 1. TOOTH GEOMETRY AND MATERIAL Shape of flank: ZI [a] [Sigma] [mt] [mn] [mx] [alfn] [gamma] [z] [b1] [b2R] [b2H] [b1, b2] [Vqual] [di] ------- WORM---------------- WHEEL ---100.000 ISO 286:2010 Measure js7 90.0000 4.0000 3.9047 4.0000 20.0000 12.5288 left left 2 41 60.00 31.00 31.00 60.00 30.83 6 7 0.00 134.40 [P] [P] [n] [KA] [T] [H] [Ns] 5.302 1500.0 1.00 33.754 25000.00 0.00 4.500 4.500 73.2 587.282

Center distance (mm) Centre distance tolerance Shaft angle () Transverse module (mm) Normal module (mm) Axial module (mm) Pressure angle at normal section () Mean lead angle () Hand of gear Number of teeth Facewidth (mm) Wheel rim width b2R (mm) Wheel width b2H (mm) Facewidth for calculation (mm) Accuracy grade (manufacturing) Internal diameter gearbody (mm) Material Worm: Gear 2:

16 MnCr 5 (1), Case-carburized steel, case-hardened ISO 6336-5 Figure 9/10 (MQ), core strength >=25HRC Jominy J=12mm<HRC28 CuSn12Ni2-C-GZ, Bronze, untreated

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DIN 3996:2005 Surface hardness Pulsating shear strength (N/mm) Fatigue strength for Hertzian pressure (N/mm) Material Coefficient YW Material lubrication coefficient Tensile strength (N/mm) Yield point (N/mm) Young's modulus (N/mm) Poisson's ratio Mean roughness, Ra, tooth flank (m) Mean roughness height, Rz, flank (m) Mean roughness height, Rz, root (m) ------- WORM---------------- WHEEL ---HRC 59 HBW 95 [tauFlim] 430.00 90.00 [sigHlim] 1500.00 520.00 [YW] 0.95 [WML_PolyG] 1.75 1000.00 280.00 695.00 150.00 206000 98100 0.300 0.350 0.50 2.00 3.00 8.00 3.00 8.00

[Rm] [Rp] [E] [ny] [RAH] [RZH] [RZF]

Tool or reference profile of gear 1: Reference profile 1.20 / 0.20 / 1.0 DIN 867:1986 Dedendum coefficient Root radius factor Addendum coefficient Tip radius factor Tip form height coefficient Protuberance height factor Protuberance angle Ramp angle

[hfP*] [rhofP*] [haP*] [rhoaP*] [hFaP*] [hprP*] [alfprP] [alfKP] not topping

1.200 0.200 1.000 0.000 0.000 0.000 0.000 0.000

Tool or reference profile of gear 2: Reference profile 1.20 / 0.20 / 1.0 DIN 867:1986 Dedendum coefficient Root radius factor Addendum coefficient Tip radius factor Tip form height coefficient Protuberance height factor Protuberance angle Ramp angle

[hfP*] [rhofP*] [haP*] [rhoaP*] [hFaP*] [hprP*] [alfprP] [alfKP] not topping

1.200 0.200 1.000 0.000 0.000 0.000 0.000 0.000

Summary of reference profile gears: Dedendum reference profile (in module) Root radius reference profile (in module) Addendum reference profile (in module) Protuberance height coefficient (in module) Protuberance angle () Tip form height coefficient (in module) Ramp angle () Type of profile modification: none (only running-in) Tip relief (m)

[hfP*] [rofP*] [haP*] [hprP*] [alfprP] [hFaP*] [alfKP]

1.200 0.200 1.000 0.000 0.000 0.000 0.000

1.200 0.200 1.000 0.000 0.000 0.000 0.000

[Ca]

0.0

0.0

Lubrication type Type of oil (Own input) Lubricant base

oil bath lubrication l: ISO-VG 220 Synthetic oil based on Polyglycol

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Kinem. viscosity oil at 40 C (mm/s) Kinem. viscosity oil at 100 C (mm/s) FZG test A/8.3/90 ( ISO 14635-1:2006) Specific density at 15 C (kg/dm) Oil temperature (C)

[nu40] [nu100] [FZGtestA] [roOil] [TS]

220.00 37.00 13 1.020 73.226 ------- WORM---------------- WHEEL ---20.000 20.000

Generating angle () Pressure angle at normal section ()

[alfa0] [alfn]

Indications for the manufacture of the worm wheel according to ISO 14521: (Only valid for worm wheels which are manufactured with a hob similar to the worm.) Mean lead angle of the worm () [gamma] Transverse module (mm) [mt] Reference diameter (mm) [d] Reference operating diameter (mm) [dm] External diameter (mm) [de] Throat radius (mm) [rk] Profile shift coefficient [x-worm] Pitch on reference circle (mm) [p2]

12.5288 4.0000 164.000 164.000 181.410 14.000 0.0000 12.566

Indications for the manufacture of the worm wheel as a cylindrical gear (This specification is only a suggestion. It is necessary to do a calculation of the exact geometry using the crossed-helical calculation!) Pressure angle at Transverse section () Pressure angle at axial section () Helix angle at reference circle () Lead angle at reference diameter () Transverse module (mm) Axial module (mm) Helix angle at operating pitch circle () Operating pitch diameter (mm) Profile shift coefficient [alft] [alfx] [beta] [gamma] [mt] [mx] [betas] [dw] [x-DIN3960] ( 59.205) ( 20.448) ( 77.471) ( 12.529) ( 18.000) ( 4.000) ( 77.471) ( 36.000) ( 0.0000) 20.448 59.205 12.529 77.471 4.000 18.000 12.529 164.000 0.0000

Overall transmission ratio [itot] -20.500 Gear ratio [u] 20.500 Base helix angle () [betab] 11.762 Reference centre distance (mm) [ad] 100.000 Diametral factor q [q] 9.000 Sum of profile shift coefficients [Summexi] 0.0000 Profile shift coefficient [x-worm] 0.0000 0.0000 Profile shift (x*m) (mm) [x*mx] 0.0000 0.0000 (The profile shift is related to the axial module of the worm subject to ISO TR 14521:2010/DIN 3975:2002. ) Tip alteration (mm) Theoretical tip clearance (mm) Effective tip clearance (mm) Reference operating diameter (mm) Reference diameter (mm) Base diameter (mm) Tip diameter (mm) Tip form diameter (mm) (mm) Tip diameter allowances (mm) Root diameter (mm) Generating Profile shift coefficient Manufactured root diameter with xE (mm) [k*mn] [c] [c.e/i] [dm] [d] [db] [da] [dFa] [dFa.e/i] [Ada.e/i] [df] [xE.e/i] [df.e/i] 0.000 0.800 1.059/ 0.963 36.000 0.000 0.800 0.877/ 0.782 164.000 164.000 153.666 172.000 172.000 172.000/ 171.990 0.000/ -0.010 154.400 -0.0450/ -0.0591 154.040/ 153.927

44.000 44.000 44.000/ 43.990 0.000/ -0.010 26.400 26.400/ 26.290

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Lead height (mm) [pz] Axial pitch (mm) [px] Transverse contact ratio (approximate value following Thomas-Charchut) [eps_a] For ZI-worms: Base diameter (mm) Base lead angle () Basecylinder pitch (mm)

25.133 12.566 1.911

[db] [gamb] [pb]

18.431 23.463 11.527

2. FACTORS OF GENERAL INFLUENCE ------- WORM---------------- WHEEL ---1875.2 7162.0 -7162.0 -1875.2 2847.3 -2847.3 8343.7 2.827 0.628 2.896 2249.999 109.756

Nominal circum. force at pitch circle (N) Axial force (N) Radial force (N) Normal force (N) Circumferential speed pitch d.. (m/sec) Sliding velocity an mean circle (m/s) Number of load cycles (in mio.) Data of reference gearbox: Equivalent Young's modulus (N/mm) Surface roughness of worm (m) Center distance (mm) Transmission ratio Reference operating diameter (mm) Characteristic value for mean Hertzian pressure Characteristic value for mean lubricant gap thickness Characteristic value for mean sliding path Physical characteristic values: Characteristic value for mean lubrication Space width Characteristic value for mean Hertzian pressure Characteristic value for mean sliding path Efficiency according method C: Roller bearing with set support Bearing loss-power (kW) Number of sealings (worm-shaft) Sealing loss power (kW) Idle loss power (kW) Base friction number Size coefficient Geometry factor Roughness factor Material Coefficient YW Mean tooth friction number Tooth friction angle () Meshing efficiency (%) Mesh loss power (kW) Total loss power (kW) Total efficiency (%) Wheel bulk temperature: Lubrication type

[Ft] [Fa] [Fr] [Fn] [v] [vgm] [NL]

[EredT] [RaT] [aT] [uT] [dm1T] [pmT*] [hT*] [sT*]

150622.00 0.500 100.000 20.500 36.000 0.962 0.070 30.800

164.000

[h*] [pm*] [s*]

0.0692 0.9470 30.2850

[PVLP] [nVD] [PVD] [PV0] [muOT] [YS] [YG] [YR] [YW] [muzm] [roz] [etaz] [PVZ] [PV] [etaGes]

0.126 2 0.046 0.153 0.0245 1.000 1.006 1.000 0.950 0.0234 1.341 90.002 0.477 0.802 84.872

oil bath lubrication

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Worm submerges into lubricant Cooling area of wheel-pair (cm) Heat-transfer coefficient wheels (W/m/K) Wheel bulk temperature (C) Oil sump temperature (C)

[AR] [alfL] [theM] [theS]

50.840 24439.990 77.1 73.2

3. WEAR SUPPORT CAPABILITY ACCORDING METHOD B,C Mean lubricant gap thickness (m) [hminm] (hminm calculated with etaOM= 0.0642 Ns/m2 theM=77.1) Pressure factor [WH] Factor for lubricant structure [WS] Factor for start [WNS] Characteristic value [Kw] Wear intensity [JOT] Wear intensity [Jw] Wear path (m) [sWm] Wear removal (mm) [delWn] Permissible tooth thickness reduction (coefficient in module) [DeltaS] Permissible mass decrease (kg) Normal tooth thickness at tip cyl. (mm) [san] (mm) [san.e/i] Boundary value for flank-removal (mm) [delWlimn] Limited by: Permissible tooth thickness decrease Safety against wear [SW] Required safety [SWmin] As information: Achievable service life (with SW = 1.100) (h) [Lh] 0.2480 1.0000 2.6140 1.0000 0.6484 5.10181e-010 8.92817e-010 815829 0.728 0.300 2.907 2.778/ 2.731 1.171 1.608 1.100 36551.07

4.PITTING SUPPORT CAPABILITY ACCORDING METHOD B,C ------- WORM---------------- WHEEL ---149673.38 367.36 1.000 0.851 1.000 1.000 1.000 442.766 1.205 1.000 76640.67

Equivalent Young's modulus (N/mm) Mean flank pressure (N/mm) Life coefficient Speed factor Size coefficient Lubrication factor Ratio factor Boundary value of average flank pressure (N/mm) Safety for surface pressure on flank Required safety As information: Achievable service life (with SHmin = 1.000) (h)

[Ered] [sigHm] [ZH] [ZV] [ZS] [Zoil] [Zu] [sigHG] [SH] [SHmin] [Lh]

5. BENDING SAFETY Bearing distance l1 (mm) Distance l11 (mm) Deflection (mm) Boundary value bending (mm) Safety for bending Required safety [l1] [l11] [delm] [dellim] [Sdel] [Sdelmin] 150.000 75.000 0.030 0.080 2.632 1.000

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6. TOOTH-ROOT SUPPORT CAPABILITY ACCORDING METHOD C ------- WORM---------------- WHEEL ---Calculation taking into account the decrease of the tooth thickness due to wear (with minimum (delWn, delWlimn)) Tooth thickness at root (mm) [sft2] 9.663 Tooth form factor [YF2] 1.200 Contact ratio factor [Yeps] 0.500 Lead coefficient [Ygam] 1.024 Rim thickness (mm) [sk2] 10.000 Rim thickness coefficient [YK2] 1.000 Nominal shear stress at tooth root (N/mm) [tauF2] 35.51 No Quality reduction by small plastic deformation is accepted. Life coefficient [YNL] 1.000 Boundary value of shear stress at tooth root (N/mm) [tauFG] 90.00 Safety for Tooth root stress [SF] 2.534 Required safety [SFmin] 1.100

7. TEMPERATURE SAFETY ACCORDING METHOD C Housing with cooler Ambient temperature (C) Oil temperature (C) Boundary value oil temperature (C) Temperature safety Required safety Oil sump temperature (C) (Safety

[TU] [theOil] [theSlim] [ST=theSlim/theOil] [STmin] [theS] [theSlim/theS]

20.0 73.2 100.0 1.366 1.100 73.2 1.366)

8. ALLOWANCES FOR TOOTH THICKNESS Tooth thickness deviation Worm: Gear:

Own Input Own Input ------- WORM---------------- WHEEL ---0.000/ -0.040 -0.128/ -0.168 99.820/ 99.707 -0.180/ -0.293

Tooth thickness allowance (normal section) (mm) Backlash free center distance (mm) Backlash free center distance, allowances (mm)

[As.e/i] [aControl] [jta]

Number of teeth spanned [k] 5.000 Base tangent length (no backlash) (mm) [Wk] 54.275 Actual base tangent length ('span') (mm) [Wk.e/i] 54.155/ 54.117 Diameter of contact point (mm) [dMWk.m] 162.549 Base tangent length (span): Can only be measured, if the worm-wheel is manufactured like a cylindrical gear! Theoretical diameter of ball/pin (mm) [dm] Eff. Diameter of ball/pin (mm) [DMeff] Theor. dim. centre to ball (mm) [MrK] Actual dimension centre to ball (mm) [MrK.e/i] Diameter of contact point (mm) [dMMr.m] Diametral measurement over two balls without clearance (mm) [MdK] Actual dimension over balls (mm) [MdK.e/i] 6.545 7.000 6.615 7.000 87.190 87.034/ 86.985 164.455 174.257 173.946/ 173.848

37.166

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Theoretical dim. over 3 wires (mm) Actual dim. over 3 rolls (mm) Tooth thickness (chordal) in pitch diameter (mm) Actual chordal tooth thickness (mm) Tooth thickness on axial cut (mm) Actual tooth thickness (mm) Tooth space in axial cut (mm) Actual tooth space (mm) Reference chordal height from da.m (mm)

[Md3R] [Md3R.e/i]

46.559 46.559/ 46.452 6.132 6.004/ 5.964

['sn] 6.133 ['sn.e/i] 6.133/ 6.093 [smx] 6.283 [smx.e/i] 6.283/ 6.242 [emx] 6.283 [emx.e/i] 6.283/ 6.324 [ham1, ha2] 3.997

4.052

Centre distance allowances (mm) Circumferential backlash (transverse section) (mm) Normal backlash (mm) 9. GEAR ACCURACY

[Aa.e/i] [jt] [jn]

0.018/ -0.018 0.226/ 0.118 0.207/ 0.108

------- WORM---------------- WHEEL ---According to DIN 3974:1995: Accuracy grade Single pitch deviation (m) Difference between adjacent pitches (m) Total deviation of the slope (m) Total cumulative pitch deviation (m) Profile slope deviation (m) Profile form deviation (m) Total profile deviation (m) Concentricity deviation (m) Total tangential composite deviation (m) Tangential tooth-to-tooth composite deviation (m) [Vqual] [fpx, fp2] [fux, fu2] [Fpz] [Fp2] [fHa] [ffa] [Fa] [Fr] [Fi'] [fi'] 6 8.50 11.00 11.00 7.50 11.00 13.00 18.00 29.00 15.00 7 13.00 16.00 51.00 11.00 15.00 19.00 35.00 56.00 22.00

10. ADDITIONAL DATA Weight - calculated with da (kg) Start under load: Tooth friction number (acc. Niemann) Torque (Nm) [Mass] [muzm_S] [T1_S] 0.714 0.140 48.195 587.282 2.455

REMARKS: - Specifications with [.e/i] imply: Maximum [e] and Minimal value [i] with consideration of all tolerances - The specification of circumferential backlash (as well as the backlash-free distance for the tooth thickness check) is not yet fully checked, and serves only as a guide. The details of the chordal tooth thickness are imprecise and merely an indication (The calculation is done according to ISO TR 14521:2010/DIN 3975:2002, without taking into account the exact shape of flank.). - In ISO14521 and DIN3996, the necessary data for each material are not always complete. In such a case you get the message: "Not calculated (material data missing)'

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