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<p>Double enveloping worm gears (DEWG) offer superior load capacity, efficiency, and smoother operation than cylindrical worm gears. However, their adoption is limited due to the lack of diverse design standards and the need for complete gear casing redesigns when replacing cylindrical worm gears. A key challenge arises when using the same tooth profile as cylindrical worm gears within the original casing, causing interference between the worm teeth and casing. Reducing the number of contact teeth may address this issue; however, it would compromise the advantages of DEWG, including uniform load distribution and high torque capacity. This study proposes an optimized DEWG design methodology that ensures compatibility with existing gear casings while maintaining performance. Using the LBFGS optimization algorithm within AGMA standards, key parameters were refined to increase the number of tooth contact points to five and enlarge the throat diameter, maintaining structural integrity without requiring new casing designs. Finite element method (FEM) simulations with LS-DYNA validate the proposed design, showing significantly reduced stress levels compared to cylindrical-based DEWG models. Maximum stresses on the worm shaft and wheel gear decreased to 48 MPa and 34.48 MPa, respectively, from 122 MPa and 46.69 MPa, remaining well below material yield strengths. This approach enables seamless integration of DEWG into existing casings, reducing costs and enhancing efficiency. By eliminating the need for new casings, industries can transition to DEWG with minimal investment while maintaining high reliability and performance.</p>

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A cost-efficient hybrid double envelope worm gear design for cylindrical worm gear casing

  • 期刊论文

  • 发表日期：

    2025年9月1日

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  • Rivaldo Mersis Brilianto,
  • Haonan Qi,
  • Chul Kim

摘要

Double enveloping worm gears (DEWG) offer superior load capacity, efficiency, and smoother operation than cylindrical worm gears. However, their adoption is limited due to the lack of diverse design standards and the need for complete gear casing redesigns when replacing cylindrical worm gears. A key challenge arises when using the same tooth profile as cylindrical worm gears within the original casing, causing interference between the worm teeth and casing. Reducing the number of contact teeth may address this issue; however, it would compromise the advantages of DEWG, including uniform load distribution and high torque capacity. This study proposes an optimized DEWG design methodology that ensures compatibility with existing gear casings while maintaining performance. Using the LBFGS optimization algorithm within AGMA standards, key parameters were refined to increase the number of tooth contact points to five and enlarge the throat diameter, maintaining structural integrity without requiring new casing designs. Finite element method (FEM) simulations with LS-DYNA validate the proposed design, showing significantly reduced stress levels compared to cylindrical-based DEWG models. Maximum stresses on the worm shaft and wheel gear decreased to 48 MPa and 34.48 MPa, respectively, from 122 MPa and 46.69 MPa, remaining well below material yield strengths. This approach enables seamless integration of DEWG into existing casings, reducing costs and enhancing efficiency. By eliminating the need for new casings, industries can transition to DEWG with minimal investment while maintaining high reliability and performance.