CA LC U L AT I O N S · D ES I G N · A PPL I CAT I O N S B . 2.

made from Hostaform®

Worm gears with worm wheels
COPYRIGHT:

All rights reserved, in particular for reproduction and copying, and for distribution as well as for
translation. No part of this publication may be reproduced or processed by means of electronic
systems, reproduced or distributed (by photocopying, microfilm or any other process), without written
permission by Ticona.

© 2004 Ticona GmbH, Kelsterbach

NOTICE TO USERS:

To the best of our knowledge, the information contained in this publication is accurate, however we do
not assume any liability whatsoever for the accuracy and completeness of such information. The
information contained in this publication should not be construed as a promise or guarantee of specific
properties of our products.

Further, the analysis techniques included in this publication are often simplifications and, therefore,
approximate in nature. More vigorous analysis techniques and prototype testing are strongly
recommended to verify satisfactory part performance. Anyone intending to rely on any recommendation
or to use any equipment, processing technique or material mentioned in this publication should satisfy
themselves that they can meet all applicable safety and health standards.

It is the sole responsibility of the users to investigate whether any existing patents are infringed by the
use of the materials mentioned in this publication.

Properties of molded parts can be influenced by a wide variety of factors including, but not limited to,
material selection, additives, part design, processing conditions and environmental exposure. Any
determination of the suitability of a particular material and part design for any use contemplated by the
user is the sole responsibility of the user. The user must verify that the material, as subsequently
processed, meets the requirements of the particular product or use. The user is encouraged to test
prototypes or samples of the product under the harshest conditions to be encountered to determine the
suitability of the materials.

Material data and values included in this publication are either based on testing of laboratory test
specimens and represent data that fall within the normal range of properties for natural material or were
extracted from various published sources. All are believed to be representative. These values alone do
not represent a sufficient basis for any part design and are not intended for use in establishing
maximum, minimum, or ranges of values for specification purposes. Colorants or other additives may
cause significant variations in data values.
We strongly recommend that users seek and adhere to the manufacturer’s current instructions for
handling each material they use, and to entrust the handling of such material to adequately trained
personnel only. Please call the numbers listed for additional technical information. Call Customer
Services at the number listed for the appropriate Material Safety Data Sheets (MSDS) before
attempting to process our products. Moreover, there is a need to reduce human exposure to many
materials to the lowest practical limits in view of possible adverse effects. To the extent that any
hazards may have been mentioned in this publication, we neither suggest nor guarantee that such
hazards are the only ones that exist.

The products mentioned herein are not intended for use in medical or dental implants.

Ticona GmbH
Information Service
Tel. +49 (0) 180-584 2662 (Germany)
+49 (0) 69-305 16299 (Europe)
Fax +49 (0) 180-202 1202 (Germany and Europe)
e-mail infoservice@ticona.de
Internet www.ticona.com
Contents

1. Introduction 3 7. Calculation examples 12

7.1 Sliding speed w 12
2. Requirements for worm gears 3 7.2 Load characteristic c 13
7.3 Safety factor S against tooth breakage 13
3. Materials
8. Examples of applications 15
4. Types of worm gear 5 8.1 Cable control mechanism for a truck
4.1 Worm 5 spare wheel carrier 15
4.2 Worm wheel 5 8.2 Stirrer arm for a kitchen mixer 17
4.3 Basic tooth profile 5 8.3 Food slicer 18
8.4 Food slicer with modified
5. Important stress characteristics 6 toothprofile 19
5.1 Sliding speed w of the flanks 6 8.5 Windshield wiper drive 20
5.2 Load characteristic c 6
5.3 Flank pressure k at the pitch point 8 9. Explanation of symbols 21
5.4 Tooth breakage force FB 8
5.5 Safety factor S against tooth breakage 9 10. Literature 22

6. Design of worm gears 9

6.1 Load characteristic c 9
6.2 Flank pressure k 9
6.3 Shear strength TB 9
6.4 Flow chart for designing worm wheels
using load characteristic c 11
6.5 Flow chart for designing worm wheels
using tooth breakage force FB 11

Hostaform
Acetal
copolymer (POM)

=
registered trademark
1. Introduction 2. Requirements for
worm gears

Worm gears are characterized by silent running, high Worm gears may be called on to meet widely varying
transmission ratio in step and a relatively compact,
one requirements with regard to speed ratio, transmission
lightweight design. This has made them the preferred output, service temperatures and service life. While
type of drive for small electrical appliances such as food almost negligible transmission outputs are required for
slicers, flour mills, electric knives, carpet and upholstery electricity meters, speedometers and time switches,
cleaning equipment, etc. Because worm wheels can be outputs of up to about 400 watts may be needed for the
manufactured at low cost from especially
thermoplastics -
stirrer arms of kitchen mixers or for mincers. Drives for
polyacetals such as Hostaform worm gears are fre
-
food slicers are normally operated at room temperature,
quently used in automotive engineering as drives for while windshield wiper drives in motor vehicles have
windshield wipers, window cranks, seat and mirror to function at service temperatures ranging from about
adjusting mechanisms, etc. 40 C to +80 C. Some worm gears operate for short
periods at a time only while others must be designed for
A characteristic feature of worm gear is high sliding continuous operation. The service life required in each
speed between the flanks of the worm and worm wheel. particular case may be anything from a few to several
The heat thereby generated places a limit on the trans hundred operating hours.
missible output of worm gears. In this brochure, we give
load characteristics which can be used as an aid in In many cases, shock loads have to be absorbed such as

designing worm gears with Hostaform worm wheels. when the mechanism runs up against a stop or when the
motor is blocked by outside effetcts.

In the production of long runs, automatic gear assembly

should be possible. For these gears, once-only lubrication
must generally suffice. As little as possible of the trans
mitted output should be converted into heat. This means
that the friction coefficient of the worm/wormwheel
sliding surfaces must be as low as possible.
3. Materials Fig. l: Coefficient of friction and wear volume of three
Hostaform grades, sliding partners: I lostaform/steel

In gears with negligibly low transmitted output, both the

worm and worm wheel are frequently injection molded 0.5
from Hostaform, the Hoechst acetal copolymer.
For the more highly stressed sliding component (worm),
a slip-modified grade such as Hostaform C 9021 K
ffî Range of scatter
0.4
(injection molding grade modified with a special chalk)
or Hostaform C 9021 TF (injection molding grade
^
modified with Hostaflon PTFE) is sometimes used.
=

Combinations with Hostaform C 9021 TF have low 0.3

friction coefficients. Hostaform C 9021 K is

characterized by high wear resistance
additionally
(fig. 1).
1 ^

0.2
If different
plastics are to be chosen for the worm and
worm wheel, polybutylene terephthalate (PBT), poly

ethylene terephthalate (PET) and polyamide (PA) are

0.1
good sliding partners for Hostaform and its modifications.

Forhigh output gears, the worm is, without exception,

made from steel because of the better heat dissipation.
Even in combination with steel, Hostaform C 9021 TF
has a low friction coefficient and Hostaform C 9021 K
exhibitsmarkedly less wear. In applications where the 20
total slide
path during the service life is short (operating
hours are minimal) but increased dimensional stability
under heat is required, the glass-fiber-reinforced grade
Hostaform C 9021 GV 1/30 may be used to advantage
provided that the resulting level of wear on the steel
worm can be tolerated.
u
e

1 10

r~i EH
1 Hostaform C 9021 (basic grade)
2 Hostaform C 9021 K
3 Hostaform C 9021 TF
 4.3 Basic tooth profile
4. Types of worm gear
The lower strength of Hostaform compared with steel
can be
partially offset by suitable design measures. Thus
4.1 Worm the tooth thickness of the worm wheel (plastic) should
be greater than the tooth thickness of the worm (steel).
Depending on the production process and position of the By way of example, fig. 3 shows the basic tooth profile
shaping surfaces of the mold, the worm teeth can have of a modified tooth system. The tooth thickness sp of the
different flank shapes. A distinction is made between worm wheel on the profile center line is in the present
flank shapes A, N, I and K and the worms are accord case 59% of the pitch p while the tooth space ep accounts
ingly designated ZA, ZN, ZI, and ZK [1] The preferred
.
for 41%. In other designs, the tooth thickness/tooth space
worm shape for electrical appliances is the ZI worm ratio may be increased up to 65 : 35. This design measure
(involute worm) which is usually rolled or milled directly increases the sustainable blocking moment or tooth
onto the motor shaft. breakage force under shock stress. Modification of the
basic tooth profile usually also involves a change in
the half flank angle a which is reduced from 20 to 15
4.2 Worm wheel or 10

Fig. 2: Worm gear with cylindrical worm and different Fig. 3: Basic tooth profile of involute gear tooth
worm wheels system before and after modification

Unmodified basic profile

profile
reference
line

1 Globoidal worm wheel

2 Semi-globoidal worm wheel
effective
3 Helical gear
flank area

Injection molded worm wheels are usually designed as

helical gears (fig. 2). With these, the advantages of easy

manufacture and assembly must be weighed against the Modified basic profile
disadvantage of the theoretical
point contact between the
worm and worm wheel which gives rise to high pressure ( p =
.T-m

loadings. Lower pressure loadings are obtained with linear *p"0.59p ep=0.41p
contact such as occurs with globoidal (concave) worm
wheels. These worm wheels can be injection molded in
one piece in (more expensive) split molds or in two ÜH
pieces and then assembled.
Semigloboidal worm wheels
which offer relatively straightforward production and
part-linear contact are a compromise solution.
\w//m
5. Important Fig. 4: Design characteristics of a worm
gear

stress characteristics

5.1 Sliding speed w of the flanks

The peripheral speed v of the worm on the reference

circle is

dmi JE nt dmi ni ["mm!

v
_

60
_

19.1
(1)
s
.

Thus the sliding speed w of the flanks is

v dmt nt framl
w =
_

(2)
cos /m 19.1 cos ym l. s
.

where
Fig. 5: Diagram showing load distribution in a worm
dmi worm reference circle diameter [mm]
gear
ni worm speed [I/mm]
y m lead angle on reference circle []
(fig. 4)

5.2 Load characteristic c

In design calculations for worm gearing, the load charac

teristic c is used. This is defined as

c [N/mm2] (3)
fz b p fz b m Jt

where
F2 peripheral force on the worm wheel [N]
fz tooth number coefficient (fig. 6)
b effective width [mm]

For globoidal worm wheels, the effective width has been Fig. 6: Tooth number coefficient fz as a function of the
specified as the chord to the outside diameter dai of the tooth number Z2 of the worm wheel
worm at the height of the reference circle dmi (fig. 7) :

b =yd2ai -

d2mi [mm] (4)

where
dai worm tip circle diameter [mm]
dmi worm reference circle diameter [mm]

p axial pitch of the worm [mm]

J3
=
transverse pitch of the worm wheel
3
C

m module [mm] ,
m =
1
cos ym I
where mn real pitch module
ym lead angle on reference circle (fig. 4) 0.6
0 20 30 40 50 60 70 80

This definition has been adopted for the semi-globoidal Number of teeth z2 on the worm wheel
worm wheel and for the helical gear.
 In the case of the worm wheel bearing where the worm
7: Effective width b on globoidal and helical wheel runs on a steel shaft, losses of 5-8% can be
worm wheels
expected, depending on lubrication.

The efficiency rjL2 is thus

rjL2 = 0.92 -0.95

For the tooth system efficiency r)z, the following applies

(fig- 8)

tan 7r
Jfc =
(8)
tan(ym+ Q)

where
ym lead angle on reference circle
tan o =
,M coefficient of friction between the worm and
wheel helical wheel worm wheel
globoidal worm worm

Fig. 8 shows the tooth system efficiency rj z as a function

For the peripheral force on the worm wheel, the follow of the lead angle the reference circle ym for a friction
on

ing applies (fig. 5): coefficient range of // 0.05-0.3. The smallest coefficient
=

corresponds approximately to the initial situation when

'""' there is sufficient lubricant between the flanks. The
fi-1* [N] (5)
d2 n2 771,2
Fig. 8: Tooth system efficiency 1J2 as a function
where of the lead angle on the reference circle ym for various
P2 effective power on the worm wheel [W] coefficients of friction ft,
d2 pitch circle diameter of the worm wheel [mm]
??L2 efficiency of the worm wheel bearing
n2 speed of the worm wheel [1/min]

The effective power P2 on the wheel requires a drive

power on the worm PI of

P.-/*- ï/ges.
[N] (6)

where
%es. over all transmission efficiency of the gearing.

In calculating the overall transmission efficiency of the

gears in question here, it is necessary to take into account
the tooth system losses, expressed as the tooth system
efficieny fjz, the worm bearing losses rju and worm
wheel bearing losses 7jL2:

%s. =
î?z
'

1lU 1/L2 (7)

The worm bearing losses with sintered iron or sintered

bronze bearings or with deep groove ball
bearings may
be estimated as 3-5% per bearing point [2], so that 3 5 10 20 30

Lead angle on reference circle ym

r?u = 0.90 -0.94
coefficient of friction JÀ 0.3 applies broadly to the dry
=

FB=TB-2At [N] (12)

sliding combination POM/steel. The friction coefficients
of the POM grades modified with PTFE, lubricants or
wear-reducing additives come in the middle of the range where
GM 0.15 -0.25).
=
TTB shear strength (fig. 12) [N/mm2]
A shear-stressed area of a tooth [mm2]
t number of engaged teeth
5.3 Flank pressure k at the pitch point 2* At =
Ages.

The flank pressure k is obtained from Hertz's law and

Fig. 9: Diagram of the engaged worm wheel teeth to
related to the curvature conditions of the flanks at the
determine shear-stressed areas 2"At
pitch point, which vary according to the different flank
shapes.

For flank shape I (involute worm) [1], the following

applies:

F,
k =
[N/mm2] (9)
b-da-fj

where
Fa peripheral force [N]
b effective width [mm]
d2 pitch circle diameter of the worm wheel [mm]
fj transverse pressure angle factor for ZI worms

fj =
cos yg sin y g (10) The number of engaged teeth is calculated as follows
(fig- 9):
y g lead angle on the base cylinder
t =
(13)
cos yg = cos ym cos a m (11) <P
where
half flank angle of the basic profile (fig. 3) <p =
-

[] pitch angle
z2 number of teeth on the worm wheel;
5.4 Tooth breakage force FB
this number is rounded off to the nearest lower whole
number.
An important criterion for the serviceability of worm

gears is their resistance to tooth fracture. This is parti

y. is calculated as follows:
cularly important for gears in which shock stress is likely
to occur. This is the for example, in mincer drives
case,
ra2 2mn
since in addition pieces of bone may get into the
to meat, y. = 2 arc cos
ro

machine and can block the drive. Another example is the (14)
windshield wiper drive, which is sometimes called upon
where
to free a solidly frozen wiper in winter. There are also
ra2 worm wheel tip circle radius [mm]
drives which run up against a stop such as window crank
mn real pitch module [mm]
drives in motor vehicles, which switch off the motor
when the stop is contacted.
The formula for calculating the shear-stressed area of
tooth is:
Overloading trials have shown that the tooth breakage
force FB is the product of the shear strength TB of the
A = b sm [mm2]
material and the sum of the shear-stressed areas of the (15)
engaged worm wheel teeth:
where
sm average width of the shear-stressed surface [mm]
b length of the arc (fig. 9) [mm]
The width of the shear-stressed surface varies over the
tooth height in accordance with the change in tooth
6. Design of worm gears
thickness with tooth height and also in accordance with
the inclination of the individual tooth to the longitudinal
axis of the worm The average shear-
(pitch angle <p). 6.1 Load characteristic c

stressed surface width is about 85% of the tooth thick

ness s on the pitch circle. Fig. 10 shows the limit curves for the load characteristic c

in helical gears and semi-globoidal worm wheels made

0.85 0.85 from Hostaform as a function of sliding speed w. The
-y-jr [mm] (16)
=
sm -s-

curves were determined in tests on actual worm gears

and indicate the limitation on transmitted output in con
The arc length b of the individual shear-stressed surfaces
is calculated follows
tinuous operation arising mainly from heat development.
as (fig. 9): For the sake of comparison, the limit for bronze
curve

worm wheels is also shown. Gears operating for short

b =
2-A-ral [mm] (17)
periods at a time only tend to permit a higher load
1 (18) characteristic but it should be remembered that because
where À ~

arc cos
lid plastics have low thermal conductivity, the flank tem
where perature can very quickly rise to unacceptably high
values.
A angle in radian measure
1 side adjacent to A (fig. 9) [mm]
rai worm tip circle radius [mm]
6.2 Flank pressure k

Since the shear-stressed surfaces of the individual teeth

We know from helical gears that wear of the tooth flanks
are symmetric with respect to the center line, only the
in dry running operation depends primarily on flank
area of half the shear-stressed surfaces need be calculated.
pressure. The limit curve shown in fig. 11 for practically
With an even number t of engaged teeth, then t/2 shear-
tested gears gives an indication as to the values up to
stressed surface areas must be calculated. If, as in fig. 9,
which excessive wear is avoided. For the sake of compa
there is an odd number of worm teeth engaged with the
rison, the flank pressure range for bronze worm wheels
worm then shear-stressed surface areas must be is given.
calculated.

For an odd number of gear teeth t: 6.3 Shear strength TB

lu =
a -

ra2 cos (x (p) [mm] (19a) Fig. 12 shows the shear strength determined in the over
loading trials described in section 5.4 as a function of
a r2 + rmi (fig. 4) [mm]
temperature. The product of the shear strength TB and
t-1 the shear-stressed area A of the engaged teeth enables an
For x, use 0 to
2 estimation of tooth breakage force FB, formula (12), to be
made.
For an even number of teeth t:

Ig =
a -

ra2 cos
|x -^- }
+ [mm] (19b)

t-2
For x, use 0 to '

5.5 Safety factor S against tooth breakage

The safety factor S against tooth breakage is the ratio of

the tooth breakage force FB to the maximum peripheral
force F2 max.

S
-FB
=
(20)
-T2 max.
 Fig. 10: Limit curves of permissible
load characteristic c as a function of the
sliding speed w of the tooth flanks

10 m/s

Sliding speed w

Fig. 11: Limit curves of flank pressure

k as a function of the sliding speed w
of the tooth flanks, determined on

practically tested gears

5 6

Sliding speed w

60
Fig. 12: Shear strength TB determined
N/mm2
on Hostaform worm wheels as a func
50 tion of temperature

40

|
30
Calculation example,
section 7.
J/5 20

10

10 20 30 40 50 60 70 80 90 100 110
C
Temperature

10
6.4 Flow chart for designing worm wheels using load 6.5 Flow chart for designing worm wheels using tooth
characteristic c breakage force FB

Given: Given:

Output PI [W] or torque MI [N m] Output PI [W] or torque Mi [N m]

Speeds n^ n2 [1/min] Speeds ni; n2 [1/min]

Calculation of peripheral force F2 Calculation of peripheral force F2

on the worm wheel: on the worm wheel:

as in flow chart 6.4

P, m/n2 ??i 19.1 103
F2 =
_

[N]
4-
2
'

H] 1
Determination of the number t of
?i =
??Li Wz
engaged teeth:
riz see fig. 8 (assume // =
0.1)
7?u 0.90 to 0.94

f-

P2 19.1 Iff 9
or F2 =
j [N]
d2 n2 ^u
360^
<P =

0.92 0.95 z2
7?L2 =
to

r*2 -

2mn
^F^Mr^rVn^-jg! ^ x =
T
2 arc cos
ra2

Determination of c valui Calculation of the total shear-stressed area Ages.:

(odd number of t)
Fz
c= , .
[N/mm2]
j Ages. =
2 At =
sm S b [mm2]
fz b m n

..
m r -,
fz see fig. 6 sm = 0.85 -

n LmmJ

b =
]/d2al -
d2ml [mm] 2 b according to section 5.4:

b = 2 A ral [mm]
Determination of sliding speed w:

A =
arc cos
-

[]
dmi '

ni
w =

19.1
[mm/s ] 1 =
a ra2 cos (x <p) [mm]
cos yr

,
t-1
x rrom 0 to -

Comparison of calculated c value with

Czul. f (w) see fig. 10

Calculation of tooth breakage force FB

FB =
Ages. fz [N] TB see fig. 12

Comparison of tooth breakage force FB

withperipheral force F2.

11
7. Calculation example

In a newly designed windshield wiper drive, it is necessary

to ascertain whether the worm wheel can be produced
from Hostaform.

The worm gear has the following specifications

Real pitch module mn = 1.25 mm

Lead angle on reference circle v

7m
9C
~

nip 1.25 mm
Module m = = 1.265 mm
cos yn 0.9877

Reference circle diamter of worm dmi = 7.85 mm

Tip circle diameter of worm dai = 10.35 mm

Pitch circle diameter of worm wheel d2 = 80 mm

Tip circle diameter of worm wheel da2 = 82.5 mm

Width of worm wheel B = 10 mm

Number of worm teeth zi = l

Number of worm wheel teeth z2 = 64

Speed of worm wheel nz = 70 min"1

Torque on worm wheel M2 = 6 Nm

Maximum torque on worm wheel (starting up) M2 max.

= 60 Nm

It is assumed that the worm wheel temperature can rise to a maximum of 75 C.

To assess whether Hostaform is suitable, the load charac- The worm speed is
teristic of the gear is calculated and compared with the
c

permissible value for Hostaform worm wheels. In addi =

n, n2
tion, it is necessary to determine the sliding speed w. It is zi
also important to examine whether the maximum torque
on the worm wheel can cause tooth fracture as the gear
=

-j1 70 min-1

starts up. = 4480 min-1

Hence
7.1 Sliding speed w
7.85 mm 4480
=
w
The sliding speed is calculated according to formula (2): 19.1 s cos 9

dml '

HI = 1864.2^
=
w
19.1 COS yn

-1.86-ï
s

12
7.2 Load characteristic c 2-M2,
"2 max.
U2

For the load characteristic, formula (3) is used:

2 60 OOP N mm
^

80mm
=
F2
c
fz '
b jt m = 1500 N

The peripheral force on the worm wheel F2 is calculated The tooth breakage force FB is calculated as the product
from the torque on the worm wheel M2 and the pitch of the total shear-stressed area and the shear strength TB
. ,
j.
d2 of the material at the maximum occurring temperature of
circle radius to give
2 75 C. The shear is (fig. 12):
strength
2-M2
F2 =
TZ = 40 N/mm2

2 6000 N mm To calculate the individual shear-stressed areas, first

_

80mm of all the number of the engaged teeth t is determined,

formula (13):
= 150 N

x ,
360C
t =
where <P =~

The load-bearing width b is calculated using formula (4): <p z2

360
b =
j/d2al-d2ml
64

=
1/(10.35 mm)2 -

(7.85 mm)2 = 5.62

= 6.74 mm For x, formula (14) aplies:

From fig. 6, the tooth number coefficient for z2 = 64 can Ta2 2mn
x = 2 arc cos
be read off as fz = 1.45. ra2

41.25 mm 2.5 mm
Thus the load characteristic = 2 arc cos
41.25 mm

= 2 20.05
150 N
c =

1.45 6.74 mm ,T 1.265 mm = 40.1

=
3.86N/mm2
Thus

From fig. 10, it can be seen that the calculated load 40.1e
t =

characteristic is above that for helical gears

slightly 5.62
(3.5 N/mm2) but below that for semi-globoidal worm
= 7.13
wheels.

As explained in section 5.4, it is necessary to round off to

7.3 Safety factor S against tooth breakage the lower number, i. e. there are 7
nearest engaged teeth.
The total shear-stressed area, which is the sum of all the
The safety factor S
against tooth breakage is the ratio of shear-stressed areas of the individual teeth, is calculated
the tooth breakage force FB to the maximum peripheral as

force F2 max.

2i A; Ages. sm '
2* b
FB
S =

2 max. where the average tooth thickness sm, formula (16) is:

m
The maximum peripheral force F2 is calculated from
max. sm = 0.85
the maximum worm wheel torque M2 max. at start-up.
= 0.85 0.5 1.265 mm jt

= 1.7 mm

13
The arc length b~ must be determined separately for the In the same way, the arc lengths for the shear-stressed
individual teeth: areas of teeth 4 and 5 (x =
2) are calculated as

b = 2 A rai (formula 17) b4/5 = 8.64 mm

where A =
arc cos
-

(fig. 9; formula 18) and for teeth 6 + 7 as

ral

in which be// = 5.51 mm

1 =
a ra2 cos (x <f) (formula 19a) The total shear-stressed area Ages. is

Since there is an odd number of engaged teeth (t =

7), AgeS. = 1.7 mm (10.62 mm + 2 10.13 mm

+ 2 8.64 mm + 2 5.51 mm)

the value given to x should be 0 to -

,
i. e. 0 to 3.
= 100.61 mm2

Center tooth 1 (x =
0): With a shear strength at 75 C of 40 N/mm2 (fig. 12),
the tooth breakage force (formula 12) is:
1[ = a ra2 cos (0 <p)
a =
r2 + rm! FB =
rB I At
= 43.93 mm
= 40 N/mm2 100.61 mm2
1, = 43.93 mm -

41.25 mm 1
= 4024.4 N
= 2.68 mm

A = arc cos
rai
Hence the safety factor against tooth breakage
2.68
=
arc cos
5.17
(formula 20) is:

= 58.8 A 1.026 rad

FB
S =

*2 max.
Hence
4024.4 N
_

1500 N
b =
AI dai
= 2.7
= 1.026 10.35 mm

= 10.62 mm

Conclusion:
Teeth 2 + 3 (x =
1):
Hostaform C can be used for the worm wheel if the
wheel is designed semi-globoidal type. Since the
as a
k/3 =
a -

ra2 cos (1 <p)

calculated load characteristic is only slightly higher than
= 43.93 mm -
41.25 mm cos 5.62
that for helical gears, it would seem to be worth trying
= 43.93 mm -

41.05 mm
a helical gear design in order to take advantage of the
= 2.88 mm
more straightforward assembly. There is a sufficient
2.88
/ 2/3 =
arc cos factor of safety against tooth breakage despite the 10 times
-y^-
= 56.1 0.979 rad
higher starting torque with this type of gear.

bz/3 = A 2/3 dai

= 0.979 10.35 mm

= 10.13 mm

14
8. Examples of applications

Photo 1

8.1 Cable control mechanism for a truck spare wheel With the tooth number coefficient for z2 = 20 (fig. 6)
carrier
fz = 0.65
Photo 1 shows a worm and a worm wheel made from
high-impact Hostaform T 1020 for the manually operated the load characteristic
cable ofspare wheel carrier mechanism on a truck.
a

The maximum spare wheel weight is 1500 N. The largest c = 10.7 N/mm2.

possible winding radius on the cable drum corresponds

The sliding speed w is negligibly small.
to the pitch circle radius of the worm wheel -~

so that

the peripheral force on the worm wheel is also High-molecular-weight Hostaform T 1020 was chosen
because it met the requirements for adequate toughness
F2 = 1500 N right down to low temperatures and for good wear
properties even when the gear flanks were contaminated
A drawing of the worm and worm wheel with the tooth with dirt, as a practical trial showed.
system specifications is shown in fig. 13.

The load-bearing width b of the semi-globoidal worm

wheel is composed of a curved and a straight part. The
curved part is calculated according to formula (4).

b = 0.5 ^d2,! -

d2,ml
= 0.5 ]/(87 mm)2 -

(80 mm)2
= 17.1 mm

15
 Fig. 13: Worm and worm wheel with tooth system specifications for the manually operated cable control
mechanism of a truck spare wheel carrier

** :-*

1
^\. T^xt,
'A
1 Worm wheel tooth

Number of teeth
specifications
20

I ~

J Flank angle 40
v >>v ^ J
X ///f A i

Flank direction
1 T
left

;: G O^
1
J
*fc
<9
< >
is
oc
Pitch
Helix angle
Transverse module
12.566

534'20"

*
e.
* Real pitch module 3.981

jn 1 1 Pitch circle diameter 80

1
I 1
Tip circle diameter 87
*
Root circle diameter 69.4
/, V22i s 1
1 //, ,^* 1 Center distance 60
1
//
'

f'r-**"""1
Tooth tip clearance

30 - *~

R 1.5
Worm tooth specifications
Number of teeth 1

Flank angle 40

Flank direction left

Pitch 12.566

Average lead angle 534'20"

Axial profile module 4

Real pitch module 3.981

Pitch circle diameter 42

Tip circle diameter 50

Root circle diameter 32.4

Center distance 60

Tooth tip clearance 0.8

16
Photo 2

8.2 Stirrer arm for a kitchen mixer Worm wheel: Number of teeth z2 = 50

Pitch circle diameter d2 = 66.51 mm

Photo 2 shows the stirrer arm of a kitchen mixer with a

nominal drive power rating of 300 W. The worm wheel Wheel width B = 11 mm

torque in the operating range is 0.22 Nm at a speed

n2 = 280 min"1. The worm (involute worm) is rolled
onto the motor shaft. On the worm side, the shaft runs Stress characteristics:
in a deep-groove ball bearing and at the other end in
a sintered metal bushing. The worm wheel material is Sliding speed of the flanks w = 2. 85 m/s
Hostaform C 9021.
Load-bearing width b = 6.8 mm

Load characteristic c = 1.6 N/mm2

Tooth system specifications:
Flank pressure k = 0.55 N/mm2

Worm: Number of teeth z, = 2

Module m = 1.3302 mm

Real pitch module mn = 1.25 mm

Lead angle 7m = 20

Lead direction left

Reference
circle diameter dmi = 7.31 mm

Tip circle diameter dai = 10 mm

17
Photo 3

8.3 Food sheer Worm wheel: Number of teeth z2 = 38

Addendum
Photo 3 shows twodesigns for a food slicer gear: the one modification coefficient = 0.1451
on the right has a motor mounting made from a zinc
diecasting while the mounting on the left is made from Pitch circle diameter d2 = 40.683 mm

a glass-fiber-reinforced thermoplastic. The motor shaft

Tip circle diameter daa = 42.4 mm
runs in two cup bearings made from sintered metal.

The axial thrust is absorbed by a steel ball pressed into Wheel width B = 7 mm

the motor shaft which pushes against a brass plate.

The worm wheel is made from Hostaform C 13021 in
the form of a helical gear. Drive power rating is 100 W. Stress characteristics:

Sliding speed of the flanks w = 2.2 m/s

Tooth system specifications
Load-bearing width b = 5.2 mm

Worm: Number of teeth z, = 2 Load characteristic c = 1.7N/mm2

Module m = 1.07061 mm

Lead angle ym = 20 55' 30"

Lead direction right

Reference
circle diameter dmi = 5.6 mm

Tip circle diameter dai = 7.6 mm

18
Photo 4

8.4 Food sucer with modified tooth profile

Photo 4 shows the worm gear for a food slicer with a

drive power rating of 140 W. The worm wheel with inte

grally molded sprocket wheel is injection moulded from
Hostaform C 9021. The tooth system with a real pitch
module mn 1 mm has been modified so that the tooth
=

thickness of the worm is reduced in favor of the tooth

thickness of the worm wheel. The tooth thickness of the
worm wheel on the pitch circle is 65% of pitch p and
that of the worm 35%.

Half flank angle a =10

Load characteristic c =4.47N/mm2 at a

Sliding speed w= 2.7 m/s.

19
Photo 5

8.5 Windshield wiper drive Stress characteristics:

Photo 5 shows a windshield wiper drive in which the This is a two-speed motor and so there are two load
motor power is transmitted via two worm wheels made characteristics at the two different sliding speeds:
from Hostaform C 9021 to a third spur wheel. Owing to
the opposite lead direction of the two worms, the axial n, =1860 min-' n2 = 2900 min-'
forces cancel each other out. Hence it is sufficient to M, = 700 N m M2 = 500 N m

mount the motor shaft in two radial bearings.

Ci =1.82 N/mm2 at wi = 0.64 m/s

c2 =1.3 N/mm2 at w2 = 1.0 m/s

Tooth system specifications The load-bearing width b is

Worms: Number of teeth Z, = 2

b = 4.8 mm

Module m = 0.8263 mm

Lead angle v
/m
= 14 5
J.T.J

Lead direction right and left

Reference
circle diameter dm = 6.39 mm

Tip circle diameter da = 8 mm

Worm wheels: Number of teeth z2 = 29

Pitch circle diameter d2 = 23.963 mm

Wheel width B = 7 mm

Center distance a = 15 mm

20
9. Explanation of symbols

On the basis of [2] and [5], the following symbols are

used:

Symbol Unit Explanation Symbol Unit Explanation

a mm center distance ri mm tip circle radius of the worm

Ages. mm2 total shear-stressed area of Ta2 mm tip circle radius of the worm

all engaged teeth wheel

A, mm2 shear-stressed area of one tooth mm tooth thicknes of the worm wheel
tooth on the pitch circle
b mm effective width of the worm wheel

b of the shear-stressed
mm average width of the shear-
mm arc length
stressed surface
surface

B mm width of the worm wheel

S safety factor
t number of engaged teeth
c N/mm2 load characteristic
V m/s peripheral speed of the worm on
d2 mm pitch circle diameter of the
the reference circle
worm wheel
W m/s sliding speed between the flanks
dal mm tip circle diameter of the worm

X factor
da2 mm tip circle diameter of the worm

wheel Zi number of worm teeth

dml mm reference circle diameter Z2 number of worm wheel teeth

of the worm
half flank angle of the basic profile
fj transverse pressure angle factor
lead the base
for ZI worms
rg angle on cylinder
7m lead angle on the referent circle
fz tooth number coefficient
?2 tooth system efficiency
FB N tooth breakage force
>?ges. overall efficiency
F2 N peripheral force on the worm

wheel flLl efficiency of the worm bearings

1 flank shape of the ZI worm flL2 efficiency of the worm wheel

k N/mm2 flank pressure the

bearings
at pitch point
K angle of tooth engagement arc
m mm module (axial module)
A rad center angle to the half arc length
mn mm real pitch module
H friction coefficient
M2 Nm torque on the worm wheel
Q angle of incline
ni 1/min worm speed
TB N/mm2 shear strength
n2 1/min worm wheel speed
<F pitch angle
P mm worm pitch (axial pitch)
ni n
index for worm
P, W drive power on the worm
if\tt
index for worm wheel
P2 W effective power on the worm

wheel index for even number of gear

teeth
T2 mm pitch circle radius of the worm

wheel index for odd number of gear teeth

21
10. Literature Technical plastics
Design Calculations Applications

[1] DIN 3975 Begriffe und Bestimmungsgrößen für Publications so far in this series:
Zylinderschneckengetriebe mit Achswinkel 90.
A. Technical plastics

[2] A. K. Thomas und W. Charchut: Die Tragfähigkeit A. 1.1 Grades and properties -
Hostaform
der Zahnräder A. 1.2 Grades and properties -
Hostacom
Carl Hanser Verlag, Munich 1971. A. 1.4 Grades and properties -
Hostalen GUR
A. 1.5 Grades and properties -

Celanex,
[3] B. Klein: Wirkungsgrad und Selbsthemmung Vandar, Impet
an Schneckengetrieben A. 2.1 Calculations principles
ant. Antriebstechnick 19 (1980) 9. A.2.2 Hostaform -
Characteristic values and
calculation examples
[4] R. Debrunner: Wirkungsgrade von Klein-Schnecken- A.2.3 Hostacom -
Characteristic values and
getrieben und ihre Beeinflussungsfaktoren calculation examples
ant. Antriebstechnik 19 (1980) 11.
B. Design of technical mouldings
[5] H. Schmidt: Schneckengetriebe mit Schnecken B.I.I Spur gears with gearwheels made from
räder aus Hostaform Hostaform, Celanex and Hostalen GUR
ant. Antriebstechnik 24 (1985) 3. B.2.2 Worm gears with worm wheels made from
Hostaform
B.3.1 Design calculations for snap-fit joints in

plastic parts
B.3.2 Fastening with metal screws
B.3.3 Plastic parts with integrally moulded threads
B.3.4 Design calculations for press-fit joints
B.3.5 Integral hinges in engineering plastics
B.3.7 Ultrasonic welding and assembly of
technical plastics

C. Production of technical mouldings

C.2.1 Hot runner system Indirectly heated,
-

thermally conductive torpedo

C.2.2 Hot runner system Indirectly heated,
-

thermally conductive torpedo

Design principles and examples of moulds
for processing Hostaform
C.3.1 Machining Hostaform
C.3.3 Design of mouldings made from
engineering plastics
C.3.4 Guidelines for the design of mouldings
in engineering plastics

C.3.5 Outsert moulding with Hostaform

22
 In this technical information brochure, Hoechst aims to

provide useful information for designers who

want to

exploit the properties of engineering polymers such as

Hostaform. Our technical service team will also be
pleased to advise you on materials, design and processing.

This information is based on our present state of knowl

edge and is intended to provide general notes on our

products and their uses. It should not therefore be con

strued guaranteeing specific properties of the products

as

described or their suitability for a particular application.

Any existing industrial property rights must be observed.
The quality of our products is guaranteed under our
General Conditions of Sale.

Applications involving the use of the Hoechst materials

Hostaform are developments or products of the plastics
processing industry. Hoechst as manufacturers of the
starting material will be pleased to give the names of pro
cessors of plastics for technical applications.

© Copyright by Hoechst Aktiengesellschaft

Issued in August 19967 1st edition

23
Hostaform ® , Celcon ®
polyoxymethylene copolymer (POM)

Celanex®
thermoplastic polyester (PBT)

Impet ®
thermoplastic polyester (PET)

Vandar®
thermoplastic polyester alloys

Riteflex®
thermoplastic polyester elastomer (TPE-E)

Vectra ®
liquid crystal polymer (LCP)

Fortron ®
polyphenylene sulfide (PPS)

Celstran ® , Compel ®
long fiber reinforced thermoplastics (LFRT)

GUR ®
ultra-high molecular weight polyethylene (PE-UHMW)

Europe
Ticona GmbH
Information Service
Tel.: +49 (0) 180-5 84 26 62 (Germany)
+49 (0) 69-30 51 62 99 (Europe)
Fax: +49 (0) 180-2 02 12 02
eMail: infoservice@ticona.de
Internet: www.ticona.com

Americas
Ticona LLC
Product Information Service
Tel.: +1-800-833-4882
Fax: +1-908-598-4306
eMail: prodinfo@ticona.com
Internet: www.ticona.com