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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.
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]
Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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Header DbId: egs
DbLabel: Engineering Source
An: 193715518
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PubType: Academic Journal
PubTypeId: academicJournal
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  Data: Structural and Technological Aspects of Improving the Accuracy of Worm Gears in the Processes of Design, Manufacturing, and Assembly.
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  Data: <searchLink fieldCode="AR" term="%22Kacalak%2C+Wojciech%22">Kacalak, Wojciech</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Ponomarenkow%2C+Jacek%22">Ponomarenkow, Jacek</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Tandecka%2C+Katarzyna%22">Tandecka, Katarzyna</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> katarzyna.tandecka@tu.koszalin.pl</i><br /><searchLink fieldCode="AR" term="%22Majewski%2C+Maciej%22">Majewski, Maciej</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Budniak%2C+Zbigniew%22">Budniak, Zbigniew</searchLink><relatesTo>1</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. May2026, Vol. 19 Issue 9, p1712. 32p.
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  Data: <searchLink fieldCode="DE" term="%22Manufacturing+processes%22">Manufacturing processes</searchLink><br /><searchLink fieldCode="DE" term="%22Process+optimization%22">Process optimization</searchLink><br /><searchLink fieldCode="DE" term="%22Gearing+machinery%22">Gearing machinery</searchLink><br /><searchLink fieldCode="DE" term="%22Multidisciplinary+design+optimization%22">Multidisciplinary design optimization</searchLink>
– Name: Abstract
  Label: Abstract
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  Data: 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]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.3390/ma19091712
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        Text: English
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      – SubjectFull: Process optimization
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      – SubjectFull: Gearing machinery
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      – SubjectFull: Multidisciplinary design optimization
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            NameFull: Tandecka, Katarzyna
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            NameFull: Majewski, Maciej
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            – D: 01
              M: 05
              Text: May2026
              Type: published
              Y: 2026
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