Computerized Modeling and Simulation of Duplex Worm-Face Gear Drives Manufacturing Process

Abstract

For mechanical transmissions, CAD systems provide flexibility and tools that can be used to perform analysis on components and to measure their performance even before they are manufactured. This paper represents an analytical study on a novel type of worm-face gear drive in which the worm is of duplex ZK-type. Such a gear set has two teeth flanks with different pitches, that facilitate stepless compensation of the tooth flank backlash or wear by means of the simple readjustment of the worm shaft. It can be used in applications that require an exact and even transmission of rotary movements or exact maintenance of a specific defined position, beside a high gear ratio in a compact space, high-load and shock capability, and reduced operating noise. The study was limited to mathematical modeling and numerical simulation of a gear set generation process using a novel 3D CAD simulation method. The method, suitable for the manufacturing process simulation of any type of gears provides a virtual 3D visual output with the ability to validate, within the precision limits of the CAD software, the accuracy of the calculation results. Some numerical examples showing 3D CAD teeth generation simulation of a duplex worm-face gear drive are presented. Numerical results relating to the analysis of virtually generated gear-set components are also provided in order to illustrate the developed theory.