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Nomenclature between worm and worm wheel is more cally the worm wheel bronze. Rank (Ref.
a Center distance (mm) easily determined and optimally adjusted. 12) explains this procedure by the chang-
leff Effective width of line contact (mm) Most often, the transmissions are imme- ing mechanical stresses in the claimed
n1 Input rotational speed (min-1) diately exposed to system operating con- surface areas in the tribological system
u Gear ratio (-) ditions and rarely subjected to run-in. tooth contact. The local Hertzian stresses
E’ Reduced e–module (N/mm²) Because the abrasive wear on the worm in the tooth contact between worm and
FN Normal force (N) wheel of large-size gear sets is minor, no worm wheel are not constant and change
K Stribeck rolling pressure (N/mm²) complete contact pattern is formed for continuously. If the yield stress is exceed-
LhI Pit lifetime in Phase I (h) most of its lifetime. And, as no math- ed, they begin with the first operating
NLI Stress reversals in Phase I (-) ematical proof determining early pitting phase and through the adaption of the
ρE Equivalent radius of curvature (mm) resistance of worm gear sets caused by worm wheel flank to the worm flank by
σH Hertzian stress (N/mm²) insufficient contact pattern has yet to be abrasive wear and a local yielding of the
σHm Mean Hertzian stress (N/mm²) documented, providing such mathemati- worm wheel material. This means that
cal proof has been the main motivation the appearance of initial pitting damage
Introduction for this research. can always be explained by the overload
In highly loaded, steel-bronze worm gear of a discrete flank section. Depending on
sets, their maximum capacity is deter- The State of the Art the present rolling strength of the worm
mined primarily by the types of damage Calculation of pitting lifetime is primar- wheel material, these loads are able to bear
incurred; i.e., “tooth breakage” and “pit- ily based on the analysis of Rank (Ref. a specific number of stress reversals until
ting.” In practice, larger-size worm gears 12), which is contained in the calculation the flank area quarries out in the form
are those with a center distance of more method DIN 3996 (Ref. 4). Calculation of pitting. According to (Ref. 12), pitting
than 200 mm. Unlike a steel-steel or steel- of pitting lifetime is recommended and its associated wear intensity can be
cast iron material combination, pitting according to (Ref. 4) if the calculated subdivided into three characteristic sec-
damage to a bronze worm wheel does not pitting safety is SH < 2.0. This is usual- tions. The pitting area described by the
necessarily lead to teeth failure. Rather, ly the case—especially for large worm pitting parameter AP10 on the worm wheel
the pitting area may in fact decrease gear sets with typical low wear intensity. can be used to define these sections. AP10
due to the gradual, abrasive wear of the Rank (Ref. 12) subjects his test gear sets represents the average pitting area of the
affected surface. Though pitting initially to a long run-in with reduced load and most damaged teeth in percentage; the
reduces the meshing area of both worm achieves a full contact pattern between value is deduced from the overlap and is
and worm wheel, it will induce noise and worm and worm wheel without prior approximately 10% of the worm wheel
reduce gear set efficiency. Therefore pre- deterioration of the flanks. Current tech- teeth. The lifecycle begins with Phase I—
cise knowledge of the pitting lifetime of nology requires therefore a completely i.e., the stage of no pitting and low wear
large, high-efficiency worm gear sets is an formed contact pattern between worm intensity. At this point there is no damage
important design criterion. and worm wheel in the calculation. to the wheel flanks; the gear set, with its
To facilitate actual assembly of a worm Pitting is generally ascribed to a sur- still fragmentary contact pattern, is run-
gear, convex—i.e., shell-shaped—con- face spalling of the material due to repeat- in during this phase; the contact patterns
tact patterns are typically produced— ed overstepping of the allowed fatigue grows; the cutting marks and roughness
although smaller when compared to a limit and the material’s so-called “rolling peaks of flanks are straightened; and the
completely formed contact pattern. Thus strength.” Pitting occurs on the weaker of resulting peaks of Hertzian stress are par-
the initial position of the contact pattern the two rolling contact partners—typi- tially reduced. By local exceeding of the
This article originally appeared (in German) in the April 2012 issue of Antriebstechnik.
Prof. Dr.-Ing. K. Stahl Prof. Dr.-Ing. B.-R. Höhn Dr.-Ing. J. Hermes studied
studied mechanical engineering studied mechanical engineering mechanical engineering at the
at the Technische Universitaet at the Technical University Ruhr Universität in Bochum (1998-
Muenchen before serving as Darmstadt (1965-1970) and 2003) and served as research
research associate at the Gear served as an assistant lecturer associate at the Gear Research
Research Centre (FZG) at the (1970-1973) at the Institute for Centre (LMGK) at the Ruhr
Technical University Munich Machine Elements and Gears Universität Bochum (2003-2007).
1994 until 2000. In 2001 he at the Technical University In 2007 he received his Ph.D. in
received his PhD in mechanical Darmstadt prior to becoming an mechanical engineering. Over
engineering and that year started as gear development assistant professor at the university (1973-1979); in 1978, the past 10 years he has dealt with theoretical and
engineer at the BMW group in Dingolfing, subsequently he received his Ph.D. (Dr. Ing.) in mechanical engineering. experimental investigations of worm gears. Hermes'
being named head of “Prototyping, Gear Technology & In early April, 1979 Höhn worked as a technical designer core areas of expertise are numerical simulations of the
Methods” in 2003. From 2006–2009 he changed to the in the department for gear development of the Audi, and manufacturing process and the contact pattern of gears.
BMW/MINI plant in Oxford, UK, first as group leader, by 1982 was head of the department for gear research He is the leader of working group NA 060-34-14 “worm
and in 2007 as department leader for Validation Driving and design for the automaker. In 1986 Audi named Höhn gears” for DIN.
Dynamics and Powetrain. In 2009 Stahl returned to department head for both gear research and testing of
Munich, responsible for predevelopment and innovation automotive transmissions, until his departure in 1989 to Dipl.-Ing. A. Monz has
management within BMW Driving Dynamics and become head of both the Institute of Machine Elements at worked as scientific assistant
Powertrain. Stahl was then named head in 2011 of the the Technical University and of the Gear Research Centre at FZG in the field of worm gear
Institute for Machine Elements and the Gear Research (FZG). Since 2011, he has served as director emeritus of drives until February, 2012. His
Centre (FZG) at the Technische Universitaet Muenchen. the Institute. Höhn has also served as vice president for core areas of expertise are
VDI for research and development, as well as leader of tribology and load capacity
working groups 6 and 15 for ISO TC 60—calculation of of gears, both theoretical and
gears. experimental.