Structural and Technological Aspects of Improving the Accuracy of Worm Gears in the Processes of Design, Manufacturing, and Assembly.
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| Title: | Structural and Technological Aspects of Improving the Accuracy of Worm Gears in the Processes of Design, Manufacturing, and Assembly. |
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| Authors: | Kacalak, Wojciech1 (AUTHOR), Ponomarenkow, Jacek1,2 (AUTHOR), Tandecka, Katarzyna1 (AUTHOR) katarzyna.tandecka@tu.koszalin.pl, Majewski, Maciej2 (AUTHOR), Budniak, Zbigniew1 (AUTHOR) |
| Source: | Materials (1996-1944). May2026, Vol. 19 Issue 9, p1712. 32p. |
| Subjects: | Manufacturing processes, Process optimization, Gearing machinery, Multidisciplinary design optimization |
| Abstract: | Highlights: Optimization of design, grinding, and assembly has improved the precision of the worm gear system. The implementation of an axially flexible worm led to a reduction of backlash without taking apart the gearbox for modification. Assembly optimization lowered the range of backlash from 20 μm to 7–10 μm. The backlash standard deviation was decreased to about 1.8 μm after assembly optimization. This paper discusses ways to improve the kinematic accuracy of worm gears in batch production. Worm gears are used in applications where high positioning accuracy, uniform motion and vibration damping is required. The paper focuses on three main methods: design changes, manufacturing process improvements and assembly optimization. Design changes aim to reduce dimensional and shape deviations of worm and worm wheel surfaces, with focus on the axially flexible worm design, which allows for minimizing backlash without disassembly. Manufacturing refinements, especially helical surface grinding, improve gear accuracy and durability. The developed algorithm for small batch production allows for selecting components based on specific criteria and thus improves overall production quality. With respect to optimization, the backlash ranges between 2 and 22 micrometers, meaning that its entire range is 20 micrometers. However, after optimizing, the backlash range falls between 7 and 10 micrometers, depending on the criterion for optimization, which amounts to about 50 to 65 percent of the initial range. The methods and algorithms are universal and can be used in small batch and large scale production. They bring economic benefits by reducing production costs and downtime through easy backlash adjustment. [ABSTRACT FROM AUTHOR] |
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| Database: | Engineering Source |
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| Abstract: | Highlights: Optimization of design, grinding, and assembly has improved the precision of the worm gear system. The implementation of an axially flexible worm led to a reduction of backlash without taking apart the gearbox for modification. Assembly optimization lowered the range of backlash from 20 μm to 7–10 μm. The backlash standard deviation was decreased to about 1.8 μm after assembly optimization. This paper discusses ways to improve the kinematic accuracy of worm gears in batch production. Worm gears are used in applications where high positioning accuracy, uniform motion and vibration damping is required. The paper focuses on three main methods: design changes, manufacturing process improvements and assembly optimization. Design changes aim to reduce dimensional and shape deviations of worm and worm wheel surfaces, with focus on the axially flexible worm design, which allows for minimizing backlash without disassembly. Manufacturing refinements, especially helical surface grinding, improve gear accuracy and durability. The developed algorithm for small batch production allows for selecting components based on specific criteria and thus improves overall production quality. With respect to optimization, the backlash ranges between 2 and 22 micrometers, meaning that its entire range is 20 micrometers. However, after optimizing, the backlash range falls between 7 and 10 micrometers, depending on the criterion for optimization, which amounts to about 50 to 65 percent of the initial range. The methods and algorithms are universal and can be used in small batch and large scale production. They bring economic benefits by reducing production costs and downtime through easy backlash adjustment. [ABSTRACT FROM AUTHOR] |
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| ISSN: | 19961944 |
| DOI: | 10.3390/ma19091712 |
