8.5.

4 Gleason Zerol Spiral Bevel Gears

When the spiral angle βm = 0, the bevel gear is called a Zerol bevel
gear. The calculation equations of Table 8-2 for Gleason straight bevel
gears are applicable. They also should take care again of the rule of hands;
left and right of a pair must be matched. Figure 8-12 is a left-hand Zerol
bevel gear.

Fig. 8-12 Left-Hand Zerol

Bevel Gear

Table 8-6 The Calculations of Spiral Bevel Gears of the Gleason System
Example
No. Item Symbol Formula
Pinion Gear
1 Shaft Angle Σ 90°
2 Outside Radial Module m 3
3 Normal Pressure Angle αn 20°
4 Spiral Angle βm 35°
5 Number of Teeth and Spiral Hand z1, z2 20 (L) 40 (R)

6 Radial Pressure Angle αt tan–1 ( tanαn

––––––
cosβm
) 23.95680

7 Pitch Diameter d zm 60 120

( )
sinΣ
δ1 ––––––––
tan–1 z2
––
8 Pitch Cone Angle z1 +cosΣ 26.56505° 63.43495°
δ2
Σ − δ1
d2
9 Cone Distance Re –––––– 67.08204
2sinδ2
10 Face Width b It should be less than Re /3 or 10m 20
ha1 1.700m – ha2
11 Addendum 0.390m
ha2 0.460m + ––––––––– 3.4275 1.6725
(––––––––
z2 cosδ1
z1 cosδ2
)
12 Dedendum hf 1.888m – ha 2.2365 3.9915
13 Dedendum Angle θf tan (hf /Re)
–1
1.90952° 3.40519°
θa1 θf2
14 Addendum Angle 3.40519° 1.90952°
θa2 θf1
15 Outer Cone Angle δa δ + θa 29.97024° 65.34447°
16 Root Cone Angle δf δ – θf 24.65553° 60.02976°
17 Outside Diameter da d + 2ha cosδ 66.1313 121.4959
18 Pitch Apex to Crown X Recosδ – ha sinδ 58.4672 28.5041
b cosδa
19 Axial Face Width Xb –––––– 17.3563 8.3479
cosθa
2b sinδ
20 Inner Outside Diameter di da – –––––––a 46.1140 85.1224
cosθa

SECTION 9 WORM MESH

The worm mesh is another gear type used for connecting skew
shafts, usually 90°. See Figure 9-1. Worm meshes are characterized by
high velocity ratios. Also, they offer the advantage of higher load capacity
associated with their line contact in contrast to the point contact of the
crossed-helical mesh.

Fig. 9-1 Typical Worm Mesh

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9.1 Worm Mesh Geometry where:

Although the worm zw = number of threads of worm; zg = number of teeth in worm gear
tooth form can be of a zw pn
L = lead of worm = zw px = ––––––
variety, the most popular cosγ
is equivalent to a V-type
zw m
γ = lead angle = tan–1(–––––– ) = sin–1(––––– )
screw thread, as in Figure zw pn
9-1. The mating worm dw π dw
gear teeth have a helical pn = px cosγ
lead. (Note: The name
“worm wheel” is often
used interchangeably with 9.1.4 Center Distance
“worm gear”.) A cen-
tral section of the mesh, dw + Dg
(––––– + –––––)
pn zg zw
taken through the worm's C = –––––––– = –––– (9-3)
O 2 2π cosγ sinγ
axis and perpendicular
to the worm gear's axis, Fig. 9-2 Central Section of a Worm and
as shown in Figure 9-2, Worm Gear 9.2 Cylindrical Worm Gear Calculations
reveals a rack-type tooth
of the worm, and a curved Cylindrical worms may be considered cylindrical type gears with screw
involute tooth form for the worm gear. However, the involute features are threads. Generally, the mesh has a 90O shaft angle. The number of threads
only true for the central section. Sections on either side of the worm axis re- in the worm is equivalent to the number of teeth in a gear of a screw type
veal nonsymmetric and non­involute tooth profiles. Thus, a worm gear mesh gear mesh. Thus, a one-thread worm is equivalent to a one-tooth gear; and
is not a true involute mesh. Also, for conjugate action, the center distance two-threads equivalent to two-teeth, etc. Referring to Figure 9-4, for a lead
of the mesh must be an exact duplicate of that used in generating the worm angle γ, measured on the pitch cylinder, each rotation of the worm makes
gear. the thread advance one lead.
To increase the length-of-action, the worm gear is made of a throated There
shape to wrap around the worm. are four worm
tooth profiles
in JIS B 1723, γ
9.1.1 Worm Tooth Proportions as defined
below.
Worm tooth dimensions, such as addendum, dedendum, pressure Type I
angle, etc., follow the same standards as those for spur and helical gears. Worm: This
The standard values apply to the central section of the mesh. See Figure worm tooth pt
9-3a. A high pressure angle is favored and in some applications values as profile is
high as 25° and 30° are used. trapezoid in d
the radial or
axial plane. πd αt
9.1.2 Number Of Threads Type II
Worm: This
The worm can be considered resembling a helical gear with a high tooth profile
helix angle. For extremely high helix angles, there is one continuous tooth pn
is trapezoid
or thread. For slightly smaller angles, there can be two, three or even more viewed in px
threads. Thus, a worm is characterized by the number of threads, zw. the normal pn αn
surface.
9.1.3 Pitch Diameters, Lead and Lead Angle Type αx
III Worm:
Referring to Figure 9-3: This worm
zw pn is formed
Pitch diameter of worm = dw = –––––– (9-1) β
π sinγ by a cutter
zg pn in which the
Pitch diameter of worm gear = dg = –––––– (9-2) tooth profile
π cosγ
is trapezoid
L = πd tanγ
Fig. 9-4 Cylindrical Worm (Right-Hand)

px zw
pn
φ
le, γ
Lead Ang px
Addendum πd L = Worm Lead
Dedendum –––w
zw
dw π dw

(a) Tooth Proportion of (b) Development of Worm's Pitch Cylinder;

Central Section Two Thread Example: zw = 2
Fig. 9-3 Worm Tooth Proportions and Geometric Relationships

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form viewed from the radial surface or axial plane set at the lead angle. 9.2.2 Normal Module System Worm Gears
Examples are milling and grinding profile cutters.
Type IV Worm: This tooth profile is involute as viewed from the radial The equations for normal module system worm gears are based on a
surface or at the lead angle. It is an involute helicoid, and is known by that normal module, mn, and normal pressure angle, αn = 20°. See Table 9-4.
name.
Type III worm is the most popular. In this type, the normal pressure
angle αn has the tendency to become smaller than that of the cutter, αc. 9.3 Crowning Of The Worm Gear Tooth
Per JIS, Type III worm uses a radial module mt and cutter pressure
angle αc = 20° as the module and pressure angle. A special worm hob is Crowning is critically important to worm gears (worm wheels). Not
required to cut a Type III worm gear. only can it eliminate abnormal tooth contact due to incorrect assembly, but
Standard values of radial module, mt, are presented in Table 9-1. it also provides for the forming of an oil film, which enhances the lubrication
effect of the mesh. This can favorably impact endurance and transmission
Table 9-1 Radial Module of Cylindrical Worm Gears efficiency of the worm mesh. There are four methods of crowning worm
1 1.25 1.60 2.00 2.50 3.15 4.00 5.00 gears:

6.30 8.00 10.00 12.50 16.00 20.00 25.00 –– 1. Cut Worm Gear With A Hob Cutter Of Greater Pitch Diameter
Than The Worm.
Because the worm mesh couples nonparallel and nonintersecting axes,
the radial surface of the worm, or radial cross section, is the same as the A crownless worm gear
normal surface of the worm gear. Similarly, the normal surface of the worm results when it is made by using
is the radial surface of the worm gear. The common surface of the worm a hob that has an identical pitch
and worm gear is the normal surface. Using the normal module, mn, is most diameter as that of the worm.
popular. Then, an ordinary hob can be used to cut the worm gear. This crownless worm gear is
Table 9-2 presents the relationships among worm and worm gear radial very difficult to assemble cor-
W
surfaces, normal surfaces, axial surfaces, module, pressure angle, pitch and rectly. Proper tooth contact and ob or
H m
lead. a complete oil film are usually
not possible.
However, it is relatively
Table 9-2 The Relations of Cross Sections of Worm Gears
easy to obtain a crowned worm
Worm gear by cutting it with a hob
Axial Surface Normal Surface Radial Surface whose pitch diameter is slightly
mn larger than that of the worm.
mn
mx = –––– mn mt = –––– This is shown in Figure 9-6.
cosγ sinγ Fig. 9-6 The Method of Using a
This creates teeth contact in the
Greater Diameter Hob
αx = tan–1 ( tanαn
–––––
cosγ
) αn αt = tan–1 ( tanα
–––––n
sinγ
) center region with space for oil
film formation.
px = πm x pn = πm n pt = πm t
2. Recut With Hob Center Distance Adjustment.
πm n z w
L = πm x z w L = –––––– L = πm t z w tanγ
cosγ The first step is to cut the
Normal Surface Axial Surface worm gear at standard center
Radial Surface
distance. This results in no
Worm Gear crowning. Then the worm gear ∆h
NOTE: The Radial Surface is the plane perpendicular to the axis.  is finished with the same hob
by recutting with the hob axis
shifted parallel to the worm gear
axis by ±∆h. This results in a ∆h
Reference to Figure 9-4 can help the understanding of the relationships
in Table 9-2. They are similar to the relations in Formulas (6-11) and (6-12) crowning effect, shown in Figure
that the helix angle β be substituted by (90° – γ). We can consider that a 9-7.
worm with lead angle γ is almost the same as a screw gear with helix angle
(90° – γ). Fig. 9-7 Offsetting Up or Down

3. Hob Axis Inclining ∆θ From Standard Position.
9.2.1 Axial Module Worm Gears
In standard cutting, the hob axis is oriented at the proper angle to the
worm gear axis. After that, the hob axis is shifted slightly left and then right,
Table 9-3 presents the equations, for dimensions shown in Figure 9-5,
∆θ, in a plane parallel to the worm gear axis, to cut a crown effect on the
for worm gears with axial module, mx, and normal pressure angle αn = 20°.
worm gear tooth. This is shown in Figure 9-8.
Only method 1 is popular. Methods 2 and 3 are seldom used.
γ

df1
d1 rc
da1
∆θ

ax df2
d2 da2
dth
∆θ

Fig. 9-5 Dimensions of Cylindrical Worm Gears Fig. 9-8 Inclining Right or Left
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 Table 9-3 The Calculations of Axial Module System Worm Gears (See Figure 9-5)
Example
No. Item Symbol Formula
Worm Wheel
1 Axial Module mx 3
2 Normal Pressure Angle αn 20°
3 No. of Threads, No. of Teeth zw, z2 ∇ 30 (R)
d1 Q mx Note 1
4 Standard Pitch Diameter 44.000 90.000
d2 z2mx

tan–1(–––––– )
mx zw
5 Lead Angle γ 7.76517°
d1
6 Coefficient of Profile Shift xa2 – 0
d1 + d2
7 Center Distance ax –––––– + xa2 mx 67.000
2
ha1 1.00mx
8 Addendum ha2 (1.00 + xa2)mx 3.000 3.000
9 Whole Depth h 2.25mx 6.750
da1 d1 + 2ha1
10 Outside Diameter 50.000 99.000
da2 d2 + 2ha2 + mx Note 2
11 Throat Diameter dth d2 + 2ha2 – 96.000
d1
12 Throat Surface Radius ri ––– – ha1 – 19.000
2
df1 da1 – 2h
13 Root Diameter 36.500 82.500
df2 dth – 2h
∇ Double-Threaded Right-Hand Worm
Note 1: Diameter Factor,Q, means pitch diameter of worm, d1, over axial module, mx.
d1
Q = –––
mx
Note 2: There are several calculation methods of worm outside diameter da2 besides those in Table
9-3.
Note 3: The length of worm with teeth, b1, would be sufficient if:

b1 = π mx (4.5 + 0.02z 2 )
Note 4: Working blank width of worm gear be = 2m x √(Q + 1). So the actual blank width of b ≥ be +
1.5mx would be enough.

Table 9-4 The Calculations of Normal Module System Worm Gears

Example
No. Item Symbol Formula Worm
Worm
Gear
1 Normal Module mn 3
2 Normal Pressure Angle αn 20°
3 No. of Threads, No. of Teeth zw, z2 ∇ 30 (R)
4 Pitch Diameter of Worm d1 44.000 –

sin–1(––––– )
mn zw
5 Lead Angle γ 7.83748°
d1
z2 mn
6 Pitch Diameter of Worm Gear d2 ––––– – 90.8486
cosγ
7 Coefficient of Profile Shift xn2 – –0.1414
d1 + d2
8 Center Distance ax –––––– + xn2 mn 67.000
2
ha1 1.00mn
9 Addendum ha2 (1.00 + x n2)mn 3.000 2.5758

10 Whole Depth h 2.25mn 6.75

da1 d1 + 2ha1
11 Outside Diameter 50.000 99.000
da2 d2 + 2ha2 + mn
12 Throat Diameter dth d2 + 2ha2 – 96.000

13 Throat Surface Radius d1 – 19.000

ri ––– – ha1
2
df1 da1 – 2h
14 Root Diameter 36.500 82.500
df2 dth – 2h
∇ Double-Threaded Right-Hand Worm
Note: All notes are the same as those of Table 9-3.

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 4. Use A Worm With A Larger Pressure Angle Than The Worm
Gear.
0.6
This is a very complex method, both theoretically and practically.
Usually, the crowning is done to the worm gear, but in this method the 0.55
modification is on the worm. That is, to change the pressure angle and pitch
of the worm without changing the pitch line parallel to the axis, in accordance 0.5
k
with the relationships shown in Equations 9-4:
0.45
pxcosαx = px'cosαx' (9-4)
0.4
In order to raise the pressure
0.35
angle from before change, αx', to after 14° 15° 16° 17° 18° 19° 20° 21° 22° 23°
change, αx, it is necessary to increase Axial Pressure Angle αx
the axial pitch, px', to a new value, px, Fig. 9-10 The Value of Factor (k)
per Equation (9-4). The amount of
crowning is represented as the space
d1 9.4 Self-Locking Of Worm Mesh
between the worm and worm gear at
the meshing point A in Figure 9-9. This 30°
amount may be approximated by the Self-locking is a unique characteristic of worm meshes that can be put
following equation: to advantage. It is the feature that a worm can­not be dri­ven by the worm
Amount of Crowning A gear. It is very useful in the design of some equipment, such as lifting, in
px – px' d1 that the drive can stop at any position without concern that it can slip in
= k ––––––– ––– (9-5) reverse. However, in some situations it can be detrimental if the system
px' 2
requires reverse sensitivity, such as a servomechanism.
where: Fig. 9-9 Position A is the Self-locking does not occur in all worm meshes, since it requires special
Point of Determining conditions as outlined here. In this analysis, only the driving force acting
d1 = Pitch diameter of worm
Crowning Amount upon the tooth surfaces is considered without any regard to losses due to
k = Factor from Table 9-5 and
bearing friction, lubricant agitation, etc. The governing conditions are as
Figure 9-10
follows:
px = Axial pitch after change
px' = Axial pitch before change Table 9-5 The Value of Factor k
αx 14.5° 17.5° 20° 22.5° Let Fu1 = tangential driving force of worm
k 0.55 0.46 0.41 0.375 Then, Fu1 = Fn (cosαn sinγ – µ cosγ) (9-6)
An example of calculating worm
crowning is shown in Table 9-6.
where:
αn = normal pressure angle
Because the theory and equations of these methods are so
γ = lead angle of worm
complicated, they are beyond the scope of this treatment. Usually, all stock
µ = coefficient of friction
worm gears are produced with crowning.
Fn = normal driving force of worm

If Fu1 > 0 then there is no self-locking effect at all. Therefore, Fu1 ≤ 0 is

Table 9-6 The Calculation of Worm Crowning the critical limit of self-locking.

No. Item Symbol Formula Example Let αn in Equation (9-6) be 20°, then the condition:
Before Crowning
1 Axial Module mx' 3 Fu1 ≤ 0 will become:
2 Normal Pressure Angle αn' 20°
(cos20° sinγ – µcosγ) ≤ 0
3 Number of Threads of Worm zw 2
4 Pitch Diameter of Worm d1 44.000
Figure 9-11 shows the critical limit of self-locking for lead angle γ and
mx' zw
5 Lead Angle γ' tan (–––––
–1
) 7.765166° coefficient of friction µ. Practically, it is very hard to assess the exact value
d1 of coefficient of friction µ. Further, the bearing loss, lubricant agitation loss,
tanα n'
6 Axial Pressure Angle αx' tan–1(–––––– ) 20.170236° etc. can add many side effects. Therefore, it is not easy to establish precise
cosγ' self-locking conditions. However, it is true that the smaller the lead angle γ,
7 Axial Pitch px' πmx' 9.424778 the more likely the self-locking condition will occur.
8 Lead L' πmx' zv 18.849556
9 Amount of Crowning CR'
* 0.04 0.20
10 Factor (k) k From Table 9-5 0.41
Coefficient of friction µ

After Crowning
­ 0.15
2CR
11 Axial Pitch tx tx' (––––– + 1) 9.466573
kd1 0.10
px'
12 Axial Pressure Angle αx cos–1(––– cosαx') 20.847973°
px
px 0.05
13 Axial Module mx ––– 3.013304
π
tan–1(––––– )
mx zw 0
14 Lead Angle γ 7.799179° 0 3° 6° 9° 12°
d1
Lead angle γ
15 Normal Pressure Angle αn tan (tanαx cosγ)
–1
20.671494°
Fig. 9-11 The Critical Limit of Self-locking of
16 Lead L πm x z w 18.933146 Lead Angle γ and
*It should be determined by considering the size of tooth contact surface. Coefficient of Friction µ

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