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QUAID-E-AWAM UNIVERSITY OF ENGINEERING,

SCIENCE & TECHNOLOGY, NAWABSHAH SINDH.

Grass Cutting Machine

Gear Design
Machine Design & CAD - II POWER TRANSMISSION SYSTEM
DESIGN PROJECT REPORT

KHALIL RAZA BHATTI 07ME40

5/12/2010
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Content

Introduction
Problem Definition
Project Objectives
Design Methodology
Working Drawing
Conclusion

Introduction

GRASS CUTTING MACHINE:

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 IT IS SIMPLY THE MACHINE WHICH CONSIST OF ROTATING

BLADES POWERED BY ELECTRIC MOTOR OR BY HAND, GRASS
IS FED AT ITS BACK, THRROUGH THE GEAR MECHANISM IT IS
COMPRESSED & SHIFTED TROWARDS FRONT AT ROTATING
BLADES WHERE THE GRASS IS CUT.

As it has been stated earlier that our

main focus of project is on the design
of worm gears so in that connection
we need to define what are the worm
gears are?

Worm Gears:
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A worm drive is a gear arrangement in

which a worm (which is a gear in the
form of a screw) meshes with a worm
gear (which is similar in appearance to
a spur gear, and is also called a worm
wheel). The terminology is often
confused by imprecise use of the
term worm gear to refer to the worm,
the worm gear, or the worm drive as a
unit. Like other gear arrangements, a
worm drive can reduce rotational
speed or allow higher torque to be
transmitted. The image shows a section of a gear box with a bronze worm
gear being driven by a worm. A worm is an example of a screw, one of the
six simple machines.
A gearbox designed using a worm and worm-wheel will be considerably
smaller than one made from plain spur gears and has its drive axes at 90°
to each other. With a single start worm, for each 360° turn of the worm, the
worm-gear advances only one tooth of the gear. Therefore, regardless of
the worm's size (sensible engineering limits notwithstanding), the gear ratio
is the "size of the worm gear - to - 1". Given a single start worm, a 20 tooth
worm gear will reduce the speed by the ratio of 20:1. With spur gears, a
gear of 12 teeth (the smallest size permissible, if designed to good
engineering practices) would have to be matched with a 240 tooth gear to
achieve the same ratio of 20:1.
Therefore, if the diametrical pitch (DP)
of each gear was the same, then, in
terms of the physical size of the 240
tooth gear to that of the 20 tooth gear,
the worm arrangement is considerably
smaller in volume
There are three different types of
gears that can go in a worm drive.
The first are non-throated worm gears.
These don't have a throat, or groove, machined around the circumference
around either the worm or worm wheel. The second are single-throated
worm gears,in which the worm wheel is throated. The final type are double-
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throated worm gears, which have both gears throated. This type of gearing
can support the highest loading.
An enveloping (hourglass) worm has one or more teeth and increases in
diameter from its middle portion toward both ends.
Double-enveloping wormgearing comprises enveloping worms mated with
fully enveloping wormgears. It is also known as globoidal wormgearing.

Problem Definition

To examine the design of worm gears of grass cutting

machine with its all type of parameters and forces that are
responsible to transmit the particular amount of power by
these gears and after the calculation of these forces
afterwards the right selection of the material that could
sustain that load, also determination of individual tooth
load it could sustain while transmission of power.

Project Objectives
 TO UNDERSTAND & DEFINE THE MECHANISM AND THE
FUNCTION OF THE GRASS CUTTING MACHINE.

 TO EVALUATE THE GEARS USED IN THE GRASS CUTTING

MACHINE. THE MAIN TASK OF OUR PROJECT IS TO
DESIGN THE WORM GEARS THAT ARE THE ESSENTIAL
PARTS WORKING IN THIS TYPE OF MACHINE &
PARTICULARLY THE DESIGN OF THE GEARS USED IN IT.
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Design Methodology
INTRODUCTION

A worm gear is used when a large speed reduction ratio is required

between crossed axis shafts which do not intersect. A basic helical
gear can be used but the power which can be transmitted is low. A
worm drive consists of a large diameter worm wheel with a worm screw
meshing with teeth on the periphery of the worm wheel. The worm is
similar to a screw and the worm wheel is similar to a section of a nut.
As the worm is rotated the worm wheel is caused to rotate due to the
screw like action of the worm. The size of the worm gearset is generally
based on the centre distance between the worm and the wormwheel.

If the worm gears are machined basically as crossed helical gears the
result is a highly stress point contact gear. However normally the
wormwheel is cut with a concave as opposed to a straight width. This
is called a single envelope worm gearset. If the worm is machined with
a concave profile to effectively wrap around the wormwheel the gearset
is called a double enveloping worm gearset and has the highest power
capacity for the size. Single enveloping gearsets require accurate
alignment of the worm-wheel to ensure full line tooth contact. Double
enveloping gearsets require accurate alignment of both the worm and
the wormwheel to obtain maximum face contact.
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The worm is shown with the worm above the wormwheel. The gearset
can also be arranged with the worm below the wormwheel. Other
alignments are used less frequently.

Nomenclature

As can be seen in the above view a section through the axis of the worm
and the centre of the gear shows that , at this plane, the meshing teeth
and thread section is similar to a spur gear and has the same features

αn = Normal pressure angle = 20o as standard

γ = Worm lead angle = (180 /π ) tan-1 (z 1 / q)(deg) ..Note: for α n=
o o
20 γ should be less than 25
b a = Effective face width of worm wheel. About 2.m √ (q +1) (mm)
b l = Length of worm wheel. About 14.m. (mm)
c = clearance c min = 0,2.m cos γ , c max = 0,25.m cos γ (mm)
d 1 = Ref dia of worm (Pitch dia of worm (m)) = q.m (mm)
d a.1 = Tip diameter of worm = d 1 + 2.h a.1 (mm)
d 2 = Ref dia of worm wheel (Pitch dia of wormwheel) =( p x.z/π ) = 2.a -
d 1 (mm)
d a.2 = Tip dia worm wheel (mm)
h a.1 = Worm Thread addendum = m (mm)
h f.1 = Worm Thread dedendum , min = m.(2,2 cos γ - 1 ) , max =
m.(2,25 cos γ - 1 )(mm)
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m = Axial module = p x /π (mm)

m n = Normal module = m cos γ(mm)
M 1 = Worm torque (Nm)
M 2 = Worm wheel torque (Nm)
n 1 = Rotational speed of worm (revs /min)
n 2 = Rotational speed of wormwheel (revs /min)
p x = Axial pitch of of worm threads and circular pitch of wheel teeth ..the
pitch between adjacent threads = π. m. (mm)
p n = Normal pitch of of worm threads and gear teeth (m)
q = diameter factor selected from (6 6,5 7 7,5 8 8,5 9 10 11
12 13 14 17 20 )
p z = Lead of worm = p x. z 1 (mm).. Distance the thread advances in one
rev'n of the worm. For a 2-start worm the lead = 2 . p x
R g = Reduction Ratio
q = Worm diameter factor = d 1 / m - (Allows module to be applied to
worm )
µ = coefficient of friction
η= Efficiency
Vs = Worm-gear sliding velocity ( m/s)
z 1 = Number of threads (starts) on worm
z 2 = Number of teeth on wormwheel

Worm gear design parameters

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Worm gears provide a normal single reduction range of 5:1 to 75-1. The
pitch line velocity is ideally up to 30 m/s. The efficiency of a worm gear
ranges from 98% for the lowest ratios to 20% for the highest ratios. As
the frictional heat generation is generally high the worm box is designed
disperse heat to the surroundings and lubrication is and essential
requirement. Worm gears are quiet in operation. Worm gears at the
higher ratios are inherently self locking - the worm can drive the gear but
the gear cannot drive the worm. A worm gear can provide a 50:1 speed
reduction but not a 1:50 speed increase....(In practice a worm should not
be used a braking device for safety linked systems e.g hoists. . Some
material and operating conditions can result in a wormgear backsliding )

The worm gear action is a sliding action which results in significant

frictional losses. The ideal combination of gear materials is for a case
hardened alloy steel worm (ground finished) with a phosphor bronze
gear. Other combinations are used for gears with comparatively light
loads.

Specifications

BS721 Pt2 1983 Specification for worm gearing Metric units.

This standard is current (2004) and provides information on tooth form,
dimensions of gearing, tolerances for four classes of gears according to
function and accuracy, calculation of load capacity and information to be
given on drawings.

Worm Gear Designation

Very simply a pair of worm gears can be defined by designation of the

number of threads in the worm ,the number of teeth on the wormwheel,
the diameter factor and the axial module i.e z1,z2, q, m .

This information together with the centre distance ( a ) is enough to

enable calculation of and any dimension of a worm gear using the
formulea available.

Worm teeth Profile

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The sketch below shows the normal (not axial) worm tooth profile as indicated
in BS 721-2 for unit axial module (m = 1mm) other module teeth are in
proportion e.g. 2mm module teeth are 2 times larger

Typical axial modules values (m) used for worm gears are

0,5 0,6 0,8 1,0 1,25 1,6 2,0 2,5 3,15 4,0 5,0 6,3 8,0 10,0 12,5
16,0 20,0 25,0 32,0 40,0 50,0

Materials used for gears

Material Notes applications

Worm
Acetal / Toys, domestic appliances,
Low Cost, low duty
Nylon instruments
Excellent machinability, Used infrequently in modern
Cast Iron
medium friction. machinery
Carbon Low cost, reasonable Power gears with medium
Steel strength rating.
Hardened High strength, good Power gears with high rating
Steel durability for extended life
Wormwheel
Acetal Toys, domestic appliances,
Low Cost, low duty
/Nylon instruments
Reasonable strength, low Normal material for worm
Phos
friction and good gears with reasonable
Bronze
compatibility with steel efficiency
Cast Iron Excellent machinability, Used infrequently in modern
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medium friction. machinery

Design of a Worm Gear

The following notes relate to the principles in BS 721-2

Method associated with AGMA are shown below..

Initial sizing of worm gear.. (Mechanical)

1) Initial information generally Torque required (Nm), Input speed(rpm),

Output speed (rpm).
2) Select Materials for worm and wormwheel.
3) Calculate Ratio (R g)
4) Estimate a = Center distance (mm)
5) Set z 1 = Nearest number to (7 + 2,4 SQRT (a) ) /R g
6) Set z 2 = Next number < R g . z 1
7) Using the value of estimated centre distance (a) and No of gear teeth
( z 2 )obtain a value for q from the table below
8) d 1 = q.m (select) ..
9) d 2 = 2.a - d 1
10) Select a wormwheel face width b a (minimum =2*m*SQRT(q+1))
11) Calculate the permissible output torques for strength (M b_1 and
wear M c_1 )
12) Apply the relevent duty factors to the allowable torque and the actual
torque
13) Compare the actual values to the permissible values and repeat
process if necessary
14) Determine the friction coefficient and calculate the efficiency.
15) Calculate the Power out and the power in and the input torque

6) Complete design of gearbox including design of shafts, lubrication,

and casing ensuring sufficient heat transfer area to remove waste heat.

Initial sizing of worm gear.. (Thermal)

Worm gears are often limited not by the strength of the teeth but by the
heat generated by the low efficiency. It is necessary therefore to
determine the heat generated by the gears = (Input power - Output
power). The worm gearbox must have lubricant to remove the heat from
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the teeth in contact and sufficient area on the external surfaces to

distibute the generated heat to the local environment. This requires
completing an approximate heat transfer calculation. If the heat lost to
the environment is insufficient then the gears should be adjusted (more
starts, larger gears) or the box geometry should be adjusted, or the
worm shaft could include a fan to induced forced air flow heat loss.

Formulae

The reduction ratio of a worm gear ( R g )

Rg=z2/z1
eg a 30 tooth wheel meshing with a 2 start worm has a reduction of 15

Tangential force on worm ( F wt )= axial force on wormwheel

F wt = F ga = 2.M 1 / d 1

Axial force on worm ( F wa ) = Tangential force on gear

F wa = F gt = F wt.[ (cos α n - µ tan γ ) / (cos α n . tan γ + µ ) ]

Output torque ( M 2 ) = Tangential force on wormwheel * Wormwheel

reference diameter /2
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M 2 = F gt* d 2 / 2
Relationship between the Worm Tangential Force F wt and the Gear
Tangential force F gt

F wt = F gt.[ (cos α n . tan γ + µ ) / (cos α n - µ tan γ ) ]

Relationship between the output torque M 2and the input torque M 1

M 2 = ( M 1. d 2 / d 1 ).[ (cos α n - μ tan γ ) / (cos α n . tan γ + µ ) ]

Separating Force on worm-gearwheel ( F s )

F s = F wt.[ (sin α n ) / (cos α n . sin γ + µ .cos γ ) ]

Efficiency of Worm Gear (η )

The efficiency of the worm gear is determined by dividing the output

Torque M2 with friction = µ by the output torque with zero losses i.e µ =
0

First cancelling [( M 1. d 2 / d 1 ) / M 1. d 2 / d 1 ) ] = 1
Denominator = [(cos α n / (cos α n . tan γ ] = cot γ

η = [(cos α n - µ tan γ ) / (cos α n . tan γ + µ ) ] / cot γ

= [(cos α n - µ .tan γ ) / (cos α n + µ .cot γ )]

Sliding velocity ( V s )...(m/s)

V s (m/s ) = 0,00005236. d 1. n 1 sec γ

= 0,00005235.m.n (z 12 + q 2 ) 1/2
Peripheral velocity of wormwheel ( V p) (m/s)

V p = 0,00005236,d 2. n 2
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Friction Coefficient

Cast Iron and Phosphor Bronze .. Table x 1,15

Cast Iron and Cast Iron.. Table x 1,33
Quenched Steel and Aluminum Alloy..Table x 1,33
Steel and Steel..Table x 2

Friction coefficients - For Case Hardened Steel Worm / Phos Bros Wheel

Sliding Friction Sliding Friction

Speed Coefficient Speed Coefficient
m/s µ m/s µ

0 0,145 1,5 0,038

0,001 0,12 2 0,033
0,01 0,11 5 0,023
0,05 0,09 8 0,02
0,1 0,08 10 0,018
0,2 0,07 15 0,017
0,5 0,055 20 0,016
1 0,044 30 0,016

Worm Design /Gear Wear / Strength Equations to BS721

Note: For designing worm gears to AGMA codes AGMA method of

Designing Worm Gears

The information below relates to BS721 Pt2 1983 Specification for worm
gearing � Metric units. BS721 provides average design values
reflecting the experience of specialist gear manufacturers. The
methods have been refined by addition of various application and duty
factors as used. Generally wear is the critical factor..

Permissible Load for Strength

The permissible torque (M in Nm) on the gear teeth is obtained by use

of the equation

M b = 0,0018 X b.2σ bm.2. m. l f.2. d 2.

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( example 87,1 Nm = 0,0018 x 0,48 x 63 x 20 x 80 )

X b.2 = speed factor for bending (Worm wheel ).. See Below
σ bm.2 = Bending stress factor for Worm wheel.. See Table below
l f.2 = length of root of Worm Wheel tooth
d 2 = Reference diameter of worm wheel
m = axial module
γ = Lead angle

Permissible Torque for Wear

The permissible torque (M in Nm) on the gear teeth is obtained by use

of the equation

1,8
M c = 0,00191 X c.2σ cm.2.Z. d 2 .m

1,8
( example 33,42 Nm = 0,00191 x 0,3234 x 6,7 x 1,5157 x 80 x2)

X c.2 = Speed factor for wear ( Worm wheel )

σ cm.2 = Surface stress factor for Worm wheel
Z = Zone factor.

Length of root of worm wheel tooth

Radius of the root = R r= d 1 /2 + h ha,1 (= m) + c(= 0,25.m.cos γ )

R r= d 1 /2 + m(1 +0,25 cosγ)

-1
l f.2 = 2.R r.sin (2.R r / b a)
-1
Note: angle from sin (function) is in radians...

Speed Factor for Bending

This is a metric conversion from an imperial formula..

-0,2
X b.2 = speed factor for bending = 0,521(V)

V= Pitch circle velocity =0,00005236*d 2.n 2 (m/s)

The table below is derived from a graph in BS 721. I cannot see how
this works as a small worm has a smaller diameter compared to a large
worm and a lower speed which is not reflected in using the RPM.

Table of speed factors for bending

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RPM (n2) X b.2 RPM (n2) X b.2

1 0,62 600 0,3
10 0,56 1000 0,27
20 0,52 2000 0,23
60 0,44 4000 0,18
100 0,42 6000 0,16
200 0,37 8000 0,14
400 0,33 10000 0,13
Additional factors

The formula for the acceptable torque for wear should be modified to allow
additional factors which affect the Allowable torque M c

M c2 = M c. Z L. Z M.Z R / K C

The torque on the wormwheel as calculated using the duty requirements (M e)

must be less than the acceptable torque M c2 for a duty of 27000 hours with
uniform loading. For loading other than this then M e should be modified as
follows

M e2 = M e. K S* K H

Thus
uniform load < 27000 hours (10 years) M e ≤ M c2
Other conditions M e2 ≤ M c2

Factors used in equations

Lubrication (Z L)..
Z L = 1 if correct oil with anti-scoring additive else a lower value should be
selected

Lubricant (Z M)..
Z L = 1 for Oil bath lubrication at V s < 10 m /s
Z L = 0,815 Oil bath lubrication at 10 m/s < V s < 14 m /s
Z L = 1 Forced circulation lubrication

Surface roughness (Z R ) ..
Z R = 1 if Worm Surface Texture < 3µ m and Wormwheel < 12 µm
else use less than 1

Tooth contact factor (K C

This relates to the quality and rigidity of gears . Use 1 for first estimate
K C = 1 For grade A gears with > 40% height and > 50% width contact
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= 1,3 - 1,4 For grade A gears with > 30% height and > 35% width contact
= 1,5-1,7 For grade A gears with > 20% height and > 20% width contact

Starting factor (K S) ..
K S =1 for < 2 Starts per hour
=1,07 for 2- 5 Starts per hour
=1,13 for 5-10 Starts per hour
=1,18 more than 10 Starts per hour

Time / Duty factor (K H) ..

K H for 27000 hours life (10 years) with uniform driver and driven loads
For other conditions see table below

Tables for use with BS 721 equations

Speed Factors

X c.2 = K V .K R
Note: This table is not based on the graph in BS 721-2 (figure 7) it is based on
another more easy to follow graph. At low values of sliding velocity and RPM
it agrees closely with BS 721. At higher speed velocities it gives a lower value
(e.g at 20m/s -600 RPM the value from this table for X c.2 is about 80% of the
value in BS 721-2

Table of Worm Gear Speed Factors

Note -sliding speed = Vs and Rotating speed = n2 (Wormwheel)

Sliding Rotating
KV KR
speed Speed
m/s rpm
0 1 0,5 0,98
0,1 0,75 1 0,96
0,2 0,68 2 0,92
0,5 0,6 10 0,8
1 0,55 20 0,73
2 0,5 50 0,63
5 0,42 100 0,55
10 0,34 200 0,46
20 0,24 500 0,35
30 0,16 600 0,33
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Stress Factors

Table of Worm Gear Stress Factors

Other C.Steel
0,4% 0,55%
metal P.B. C.I. Case.
C.Steel C.Steel
(Worm) H'd
Bending
Metal Wear ( σ cm )
(σbm )
(Wormwheel)
MPa MPa

Phosphor Bronze
69 8,3 8,3 9,0 15,2
Centrifugal cast
Phosphor Bronze
63 6,2 6,2 6,9 12,4
Sand Cast Chilled
Phosphor Bronze
49 4,6 4,6 5,3 10,3
Sand Cast
Grey Cast Iron 40 6,2 4,1 4,1 4,1 5,2
0,4% Carbon steel 138 10,7 6,9
0,55% Carbon
173 15,2 8,3
steel
Carbon Steel
276 48,3 30,3 15,2
(Case hardened)

Zone Factor (Z)

1/2 1/2
If b a < 2,3 (q +1) Then Z = (Basic Zone factor ) . b a /2 (q +1)
1/2
If b a > 2,3 (q +1) Then Z = (Basic Zone factor ) .1,15

Table of Basic Zone Factors

q

z
6 6,5 7 7,5 8 8,5 9 9,5 10 11 12 13 14 17 20
1
1 1,04 1,04 1,05 1,06 1,08 1,10 1,12 1,13 1,14 1,16 1,202 1,26 1,31 1,40 1,50
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5 8 2 5 4 7 8 7 3 8 2 8
0,99 1,02 1,05 1,09 1,14 1,18 1,21 1,22 1,23 1,44 1,57
2 1,25 1,28 1,32 1,36
1 8 5 9 4 3 4 3 1 7 5
0,82 0,98 1,10 1,20 1,30 1,33 1,36 1,42 1,44 1,53 1,67
3 0,89 1,26 1,35 1,393
2 9 9 9 5 3 5 2 2 2 4
0,82 0,98 1,09 1,20 1,70 1,42 1,54 1,66 1,79
4 0,83 1,38 1,46 1,49 1,515 1,57
6 1 8 4 1 8 5 6 8
0,94 0,99 1,12 1,21 1,31 1,41 1,632 1,65 1,67 1,76 1,88
5 1,05 1,49 1,55 1,61
7 1 2 6 5 7 * 2 5 5 6
1,13 1,14 1,17 1,28 1,43 1,52 1,58 1,62 1,71 1,73 1,81 1,92
6 1,22 1,35 1,694
1 5 2 7 8 1 8 5 4 3 8 8
1,31 1,40 1,45 1,61 1,70 1,84
7 1,34 1,37 1,54 1,725 1,74 1,76 1,98
6 5 2 4 4 6
1,43 1,46 1,55 1,62 1,71 1,75 1,77 1,86
8 1,5 1,738 1,96
7 2 7 3 5 3 8 8
1,60 1,64 1,76
9 1573 1,72 1,743 1,79 1,88 1,97
4 8 7
1 1,72 1,77 1,79 1,88
1,68 1,748 1,98
0 8 3 8 8
1 1,73 1,77 1,80 1,89 1,98
1,753
1 2 7 2 2 7
1 1,80 1,89 1,99
1,76 1,78
2 6 5 2
1 1,78 1,80 1,89 1,99
3 4 6 8 8
1 1,81
1,9 2
4 1

Duty Factor

Duty - time Factor K H

KH
Impact from Expected life Impact From Load
Prime mover hours Uniform Medium Strong
Load Impact impact
Uniform Load 1500 0,8 0,9 1
Motor Turbine 5000 0,9 1 1,25
Hydraulic 27000 1 1,25 1,5
motor 60000 1,25 1,5 1,75
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1500 0,9 1 1,25

Light impact 5000 1 1,25 1,5
multi-cylinder
engine 27000 1,25 1,5 1,75
60000 1,5 1,75 2
Medium 1500 1 1,25 1,5
Impact 5000 1,25 1,5 1,75
Single 27000 1,5 1,75 2
cylinder
engine 60000 1,75 2 2,25

Worm q value selection

The table below allows selection of q value which provides a reasonably

efficient worm design. The recommended centre distance value "a"
(mm)is listed for each q value against a range of z 2 (teeth number
values). The table has been produced by reference to the relevant plot
in BS 721
Example
If the number of teeth on the gear is selected as 45 and the centre
distance is 300 mm then a q value for the worm would be about 7.5

Important note: This table provides reasonable values for all worm
speeds. However at worm speeds below 300 rpm a separate plot is
provided in BS721 which produces more accurate q values. At these
lower speeds the resulting q values are approximately 1.5 higher than
the values from this table. The above example at less than 300rpm
should be increased to about 9

Table for optimum q value selection

Number of Teeth On Worm Gear (z 2)

q 20 25 30 35 40 45 50 55 60 65 70 75 80
6 150 250 380 520 700
6.5 100 150 250 350 480 660
7 70 110 170 250 350 470 620 700
7.5 50 80 120 180 240 330 420 550 670
8 25 50 80 120 180 230 300 380 470 570 700
8.5 28 90 130 130 180 220 280 350 420 500 600 700
9 40 70 100 130 170 220 280 330 400 450 520
9.5 25 50 70 100 120 150 200 230 300 350 400
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10 26 55 80 100 130 160 200 230 270 320

11 25 28 55 75 100 130 150 180 220 250
12 28 45 52 80 100 130 150 100
13 27 45 52 75 90 105

AGMA method of Designing Worm Gears

The AGMA method is provided here because it is relatively easy to use and
convenient- AGMA is all imperial and so I have used conversion values so
all calculations can be completed in metric units..

Good proportions indicate that for a centre to centre distance = C the mean
worm dia d 1 is within the range
Imperial (inches)
0,875 0,875
(C /3) ≤ d1 ≤ (C / 1,6 )

Metric ( mm)
0,875 0,875
(C /2) ≤ d1 ≤ (C / 1,07 )

The acceptable tangential load (W t) all

0,8
(W t) all = C s. d 2 .b a .C m .C v . (0,0132) (N)

The formula will result in a life of over 25000 hours with a case hardened
alloy steel worm and a phosphor bronze wheel

C s = Materials factor
b a = Effective face width of gearwheel = actual face width. but not to
exceed 0,67 . d 1
C m = Ratio factor
C v = Velocity factor
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Modified Lewis equation for stress induced in worm gear teeth .

σ a = W t / ( p n. b a. y )(N)
W t = Worm gear tangential Force (N)
o
y = 0,125 for a normal pressure angle α n = 20

The friction force = W f

W f = f.W t / (. cos φ n ) (N)

γ = worm lead angle at mean diameter

α n = normal pressure angle

The sliding velocity = V s

V s = π .n 1. d 1 / (60,000 )

d 1 = mean dia of worm (mm)

n 1 = rotational speed of worm (revs/min)

The torque generated γ at the worm gear = M b (Nm)

T G = W t .d 1 / 2000

The required friction heat loss from the worm gearbox

H loss = P in ( 1 - η )

η = gear efficiency as above.

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C s values
3
C s = 270 + 0,0063(C ) ... for C ≤ 76mm ....Else

C s (Sand cast gears ) = 1000 for d 1 ≤ 64 mm ...else... 1860 - 477 log (d 1 )

C s (Chilled cast gears ) = 1000 for d 1 ≤ 200 mm ...else ... 2052 -456 log
(d 1 )

C s (Centrifugally cast gears ) = 1000 for d 1 ≤ 635 mm ...else ... 1503 - 180
log (d 1 )

C m values

NG = Number of teeth on worm gear.

NW = Number of stards on worm gear.
mG = gear ration = NG /NW

C v values

C v (V s > 3,56 m/s ) = 0,659 exp (-0,2167 V s )

-0,571
C v (3,56 m/s ≤ V s < 15,24 m/s ) = 0,652 (V s) )

-0,774
C v (V s > 15,24 m/s ) = 1,098.( V s ) )

f values
24 | P a g e

f (V s = 0) = 0,15
0,645
f (0 < V s ≤ 0,06 m/s ) = 0,124 exp (-2,234 ( V s )
0,450
f (V s > 0,06 m/s ) = 0,103 exp (-1,1855 ( V s ) ) ) +0,012

Working Drawing
25 | P a g e

Conclusion:

In the whole task we went through number of steps where

we learnt the basic design parameters of grass cutting
machine including their use and problems encountered by
customers. Some how we could not complete our design
project but even then we have an idea now that what
basically the design is and what are the factors involving
the design. We enjoyed working on it specially visited
many places where this machine is installed and even at
shops to get the data.