Mechanical

System Design
Meaning of Mechanical System Design
Mechanical (Adjective)
◦ Using mechanisms or tools or devices

System (Noun)
◦ Instrumentality that combines interrelated interacting artifacts designed to work as a
coherent entity
◦ A group of independent but interrelated elements comprising a unified whole

Design (Verb)
◦ Make or work out a plan for; devise
◦ Plan something for a specific role or purpose or effect

Design (Noun)
◦ The act of working out the form of something (as by making a sketch or outline or
plan)
◦ An arrangement scheme
Meaning of Engineering Design
The term design covers a wide spectrum of concepts from “designer” jeans to high
temperature components in jet engines. In this course we are more interested in the
latter concepts.

Engineering Design has been defined as “The process of applying various techniques
and scientific principles for the purpose of defining a device, a process, or a system
in sufficient detail to permit its realization.”

Not all projects

are small and
simple.
Shown is an
example of a
large machine
design project
The airplane is a great example of a
continuous machine design project
Meaning: Engineering Design
Design may be-
➢ evaluating one of a device, process, or system
consisting of interrelated components
➢ a single component which modifies force creation of
the initial or conceptual design of a new device
➢ modification of an existing device to meet new
customer requirements
➢ to correct an operating problem.
Worm Gears
DESIGN OF MECHANICAL SYSTEM
Contents
Introduction
Terminology
Proportions of Worm Gears
Force Analysis
Friction in Worm Gears
Selection of Materials
Strength Rating of Worm Gears
Wear Rating of Worm Gears
Thermal Considerations
Introduction
• Worm gear drives are used to
transmit power between two non-
intersecting shafts, which are, in
general, at right angles to each
other.
• The worm gear drive consists of a
worm and a worm wheel.
• The worm is a threaded screw,
while the worm wheel is a
Worm and Worm Wheel
toothed gear.
Introduction…
Advantages of worm gear drives:
1. High speed reduction.
2. Worm gear drives are compact
3. Smooth and silent operation
4. Provision can be made for self locking
Introduction…
Drawbacks of worm gear drives:
1. Low efficiency
2. High heat generation
3. Power transmitting capacity is low (up to 100
kW).
4. Costly material (phosphor bronze) is required for
the worm wheel.
Introduction…
• It is necessary to consider the relationship
between the number of starts on the worm and
the efficiency to decide the suitability of worm
gear drive for a particular application.
• Two guidelines are as follows:
1. Single-threaded worm gives large speed
reduction, however, the efficiency is low.
2. Multi-threaded worm gives high efficiency,
however, the speed reduction is low.
Worm Gears
The worm is analogous to a screw thread and
the worm gear is analogous to its nut.
In a worm gear drive, power is always
transmitted from worm to worm wheel.
Power cannot be transmitted from worm wheel
to worm. This phenomenon is called self-
locking. It is highly useful in many applications.
Velocity ratio is determined by the number of
teeth on worm gear and the number starts on
worm.

A Single Enveloping
Worm set
Worm Gears Application
Example
Applications of Worm Gear
Drives
➢ Gate control mechanisms
➢ Hoisting machines
➢ Automobile steering mechanisms
➢ Lifts
➢ Conveyors
➢ Presses
➢ Speed reducer
 When to Use Worm and
Worm Gears
High ratio speed reduction
(Gear ratio up to 200:1)
Space limitations
Right angle shafts
Non-intersecting shafts

The cut section of a worm gearbox with fins and

fan for cooling
Advantages and Disadvantages of
Worm Gear Drive
Advantages:
1. Worm gear drives operate silently and smoothly.
2. They are self-locking.
3. They occupy less space.
4. They have good meshing effectiveness.
5. They can be used for reducing speed and increasing torque.
6. High velocity ratio of the order of 200 can be obtained in a single step

Disadvantages
1. Worm gear materials are expensive.
2. Worm drives have high power losses and low transmission efficiency.
3. They produce a lot of heat.
Terminology
Worm gears are specified
and designated by four
quantities in order
z1/z2/q/m

(No. of starts on worm/

No. of teeth on wheel/
Diametral quotient/
Module)

px = Circular pitch =  m

q = d1/m
 Terminology
 = Helix angle
 = Lead angle

Lead, l = px × z1 =  m z1

tan  = Lead /  d1
=  m z 1 /  d1
=  m z1 /  qm
= z1/q

+ = /2

Center distance = (d1+d2)/2

= (mq+mz2)/2
Types of Worms
There are two types of worms.
1. Cylindrical or straight worm.
2. Cone or double enveloping worm.
Terminology

Single Enveloping Double Enveloping

Line Contact Area Contact

High Contact Pressure high wear Low Contact Pressure , Less wear
More space, Higher Weight Less space (2/3), Less Weight (1/3)
Require precise alignment (Disadvantage)
Proportions of Worm Gears
Proportions of Worm Gears
Worm
ha1 = m
h f1 = (2.2 cos  − 1)m
c = 0.2m cos 
d a1 = d1 + 2ha1 = m(q + 2 )
d f1 = d1 − 2h f1 = m(q + 2 − 4.4 cos  )

Worm Wheel

ha2 = m(2 cos  − 1)

h f1 = m(1 + 0.2 cos  )
d a2 = d 2 + 2ha2 = mz 2 + 2m(2 cos  − 1)
d f 2 = d 2 − 2h f 2 = mz 2 − 2m(1 + 0.2 cos  )
Numerical Example
A pair of worm gears is designated as 1/30/10/8. Calculate
i) Center distance
Ii) Speed reduction
Iii) The dimensions of the worm
Iv) The dimensions of the worm wheel.
Solution:
Given: z1= 1 , z2 = 30 , q = 10, m = 8
Center distance = (mq+mz2)/2 = (80+240)/2 = 160 mm
Face Width
Derivation: Consider triangle AOC

( AC )2 = ( AO )2 − (OC )2
2
 F   d a1   d1 
2 2

  =  −  
2  2  2
 F   m(q + 2 )   qm 
2 2 2

  =  − 2 
  
2 2   
F 2 = m 2 (q + 2 ) − q 2 m 2
2

F = 2m q + 1
Length of root of Worm
Wheel, lr
Let us find length of root of worm wheel i.e.
length of arc XYZ.. Consider triangle OC1Z
CZ
sin  = 1
OZ
F
 
=   =
2 F
 d a1 + 2c  (d a1 + 2c )
 
 2 
lr = arc XYZ
= radius  angle in radians
 d a1 + 2c 
=    2
 2 
 F 
( )
lr = d a1 + 2c sin −1  
 d a + 2c 
 1 
Force Analysis
Why do we need force analysis?
 Force Analysis
Components of Tooth Force Direction of Force Components

Assumptions
1. Worm is Driving
member and wheel Driven
is driven member
2. RH Thread of worm
3. DoR of worm CCW
when looked from
left.

Consider worm as
screw and wheel as
nut. Driver
USE RH Thumb Rule

Three components of force: Tangential, Axial, Radial

Force Analysis
Components of Tooth Force
-Pressure angle
- Lead angle
P- Normal Reaction force on worm

Resolving Pn further

Using expression for Pn

Friction in Worm Gears
Frictional force is significant because of Components of Frictional Force
sliding contact

Two components of frictional force are:

i) Tangential direction
ii) Axial direction

We need to superimpose components of

normal force and Friction force
appropriately

After superimposition
 Friction in Worm Gears
Finally Components of Frictional Force

Generally Pt is known from Torque

transmitted. Mt
2𝑀𝑡
𝑃𝑡 =
𝑑1
𝑃𝑡
P=
𝑐𝑜𝑠𝛼 𝑠𝑖𝑛𝛾 + 𝜇𝑐𝑜𝑠𝛾
𝑃𝑡 𝑐𝑜𝑠𝛼 𝑐𝑜𝑠𝛾 − 𝜇𝑠𝑖𝑛𝛾
Hence, 𝑃𝑎 =
𝑐𝑜𝑠𝛼 𝑠𝑖𝑛𝛾 + 𝜇𝑐𝑜𝑠𝛾
𝑃𝑡 𝑠𝑖𝑛𝛼
𝑃𝑟 =
𝑐𝑜𝑠𝛼 𝑠𝑖𝑛𝛾 + 𝜇𝑐𝑜𝑠𝛾
Numerical Example
A pair of worm and worm wheel is designated as 2/52/10/4. 10 kW
power at 720 rpm is supplied to the worm shaft. The coefficient of
friction is 0.04 and the pressure angle is 20. Calculate the components
of resultant gear tooth forces acting on worm wheel.

Answer:
27105 N, 6631 N, 10147 N
Friction in Worm Gears
▪ Coefficient of friction  depends on the
rubbing speed.
▪ Rubbing speed is the relative velocity
between the worm and worm wheel.
▪ Pitchline velocity for worm, V1
d1n1
V1 =
60 1000
▪ From velocity triangle
V1 d1n1
Vs = =
cos  60000  cos 
Velocity of Sliding
 Friction in Worm Gears
Coefficient of Friction for Worm Gears
Variation of coefficient
of friction with respect
to rubbing velocity is
shown in adjoining
graph.
Efficiency of Worm Gear Drive
Efficiency of drive n2 1
=
Power Output n1 i
=
Power Input

(P2 )t  d 2  n2 (P )  i tan  (P )  tan 

= 2 = 1a = 1a
(P1 )t  d1  n1 (P1 )t  i (P1 )t
2
P(cos  cos  −  sin  ) tan  (cos  −  tan  )
= =
P(cos  sin  +  cos  ) (cos  +  cot  )
Use
cos  −  tan 
=
z2
d 2 mz 2 z2 z1
cos  +  cot  =
d1 mq
= =
q q
= i tan 
z1
Efficiency of Worm Gear Drive
Efficiency of worms gears is low and varies
considerably in the range of 50 to 90 %
In general, the efficiency is inversely proportional
to speed ratio, provided the coefficient of friction is
constant.
Numerical Example
A pair of worm gears is designated as 1/52/10/8. The worm rotates at
1000 rpm and the normal pressure angle is 20. Determine the
coefficient of friction (refer graph of µ vs rubbing speed) and the
efficiency of worm gears.

Answers:
Coefficient of friction: 0.027
Efficiency: 77.45 %
Spur Gear
Beam Strength of Spur Gear as per Lewis Equation
Sb = m b  b Y
where,
m = module
b = face width
b = Permissible bending stress
Y = Lewis form factor
Strength Rating of Worm
Gears…

where,
Mt- Permissible torque
Xb- Speed factor for strength Power transmitting capacity
Sb- Bending stress factor based on beam strength
lr- Length of root of the worm wheel teeth
d2- diameter of worm wheel 2n2 M t
- Lead angle kW =
m- Module
60 10 6
 Strength Rating of Worm
Gears…

Bending stress factor

 Strength Rating of Worm
Gears…
Speed factor for Worm Gears for Strength (Xb)

Speed factor
Wear Rating of Worm Gears

where,
Mt- Permissible torque
Sc- Surface stress factor Power transmitting capacity
Xc- Speed factor for wear based on beam strength
Yz – Zone factor
d2- diameter of worm wheel 2n2 M t
kW =
m- Module 60 10 6
 Wear Rating of Worm Gears…
Values of the Surface Stress Factor, Sc

Surface
Stress Factor
 Wear Rating of Worm Gears…
Values of zone factor Yz
z1 q=8 q=9 q = 10 q = 12 q = 16 q = 20
1 1.084 1.128 1.143 1.202 1.374 1.508
2 1.114 1.214 1.231 1.280 1.418 1.575
Zone Factor
4 1.204 1.380 1.460 1.515 1.634 1.798
Speed factor for Worm Gears for Wear, (Xc)
Selection of Materials
Worm
• Subjected to fluctuating stress.
• Number of stress cycles experienced is fairly large.
Hence surface endurance strength is the criterion for selection of
material.

◦ Normalized carbon steel: 40C8, 55C8

◦ Case hardened carbon steel: 10C4, 14C6 Surface hardness 60 HRC
Case depth 0.75 to 4.5 mm
◦ Alloy steel: 16Ni80Cr60, 20Ni2Mo25
◦ Nickel Chromium Steel:13Ni3Cr80, 15Ni4Cr1
Selection of Materials
Worm wheel
▪ Magnitude of contact stress is same as that of worm
▪ Number of stress cycles are reduced
▪ Profile cannot be generated by hobbing, final profile is
achieved by plastic deformation during initial stages of
service
Hence material for worm will should be soft and conformable.
It is hardened to 90-120 BHN

Materials used are:

▪ Phosphor Bronze (Sand cast)
▪ Phosphor Bronze (Sand cast chilled)
▪ Phosphor Bronze (centrifugal cast)
Numerical Example
A pair of worm and worm wheel is designated as 1/40/10/4. The input
speed of the worm is 1000 rpm. The worm wheel is made of phosphor
bronze (sand cast) and the worm is made of case hardened carbon
steel 10C4. Determine (i) Power transmitting capacity based on the
beam strength (ii) Power transmitting capacity based on wear
strength.
Given:
z1= 1, z2 = 40, q = 10, m = 4, n1 = 1000 rpm
i = z2/ z1=40
n2 = 1000/40 =25 rpm, d2 = m z2 = 4 (40)= 160
tan  = z1/q = 0.1, hence  = 5.71
Solution Ex 1
Facewidth, F=26.53 F = 2m q + 1 c = 0.2m cos 
da1 = 48 mm, C= 0.7960 mm da1 = d1 + 2ha1 = m(q + 2)
Length of tooth root, lr = 27.99 mm  F 
From table 20.2 , Sb1 = 28.2
( )
lr = d a1 + 2c sin 
−1 
 d a + 2c 
 1 
From Fig 20.13, Speed factors Xb1 = 0.27 and Xb2= 0.5
Mt1 = 2395.41 Nmm (M t )1 = 17.65 X b1Sb1ml r d 2 cos 
Mt2 = 766.52 Nmm (lower) (M t )2 = 17.65 X b 2 Sb 2 ml r d 2 cos 
Strength rating kW = 2.059 2n2 M t
kW =
60 10 6
Solution
Surface stress factors, Sc1 = 4.93 and Sc2 = 1.06
Zone factor, Yz from Table 20.4 1.143
Rubbing speed, Vs = 2.10484 m/s
From Graph, Speed factors Xc1 = 0.15 and Xc2= 0.35
Mt1 = Nmm
Mt4 = 293320 Nmm (lower)
Wear rating kW = 0.7679
Numerical Example
A pair of worm and worm wheel is designated as 1/30/10/10. The input
speed of the worm is 1200 rpm. The worm wheel is made of
centrifugally cast, phosphor bronze and the worm is made of case
hardened carbon steel 14C6. Determine the power transmitting
capacity based on the beam strength.
Given:
z1= 1, z2 = 30, q = 10, m = 10, n1 = 1200 rpm
i = z2/ z1=30
n2 = 1200/i =40 rpm, d2 = m z2 = 10 (30)= 300
tan  = z1/q = 0.1, hence  = 5.71
Numerical Example (contd)

(M t )1 = 17.65 X b1Sb1ml r d 2 cos 

(M t )2 = 17.65 X b 2 Sb 2 ml r d 2 cos 
Numerical Example (contd)
 Thermal Considerations
▪ Rate of heat generated ,
H g = 1000 (1 − ) PkW ...................................(1)
▪ The rate of heat dissipated,
Hd = K (t − t0 ) A.....................................(2)
▪ Equating equations (1) and (2)
1000 (1 −  ) PkW = K (t − to ) A...............................(3)
and we get
K (t − to ) A Power transmitting capacity based on
PkW =
1000 (1 −  ) thermal considerations
Alternativ ely,
1000 (1 −  ) PkW Resultant temperature of the lubricating
t = to +
KA oil for given power transmitting capacity
Example 20.6 Page
A pair of worm gears is designated as 1/40/10/4. The input speed of worm shaft
is 1000 rpm. The gear box has an effective surface area of 0.25 m2. A fan is
mounted on the worm shaft to circulated air over the surface of the fins. The
coefficient of heat transfer can be taken as 25 W/m2C. The permissible
temperature rise of the lubricant oil above the atmospheric temperature is
45C. The coefficient of friction is 0.35 and the normal pressure angle is 20.
Calculate the power transmitting capacity base on thermal considerations.

Given:
K (t − to ) A cos  −  tan  z1 1
t-to = 45 PkW = = tan  = =
1000 (1 −  ) cos  +  cot  q 10
Answer:

Power transmitting capacity based on thermal considerations is 1.026 kW