Manufacturing of worm face gear similar to a regular worm gear and normally no special manufacturing or inspection equipment required. Localization of the tooth contact can be done by modifying the gear cutter or the pinion. The advantage of a worm face gear versus a regular worm gear is higher driving efficiency and higher strength. The worm face gear can be designed self-locking or back derivable. It is common to design worm face gear with different pressure angle on the opposite sides of the tooth. Lower pressure angle on the front of the pinion helps to avoid undercut on the front side of the pinion thread. The high-pressure angle on the backside of the pinion prevents undercut on the gear tooth. However the amount of undercuts always depend on design of the gear set. It is possible to design a face worm gear set with equal pressure angles on both sides of the tooth like it is shown on the 3-dimentional model above.
The digital analyses originally proposed by the author make manufacturing and design of worm face cost effective and more productive. The gear tooth surface and the contact pattern can be predicted on a 3-dimentional digital models before the prototypes are manufactured. The 3-dimentional model of the worm face gear can be used for manufacturing of the gears in CNC machines. It can be less expansive for some medium quality applications or for plastic gears.
Worm gear design software
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3-dimentional simulation and modeling of the Globoid and double enveloping tooth geometry is done on special software. The software generates gear and pinion flanks to allow accurate 3d modeling in CAD like SolidWorks or other.
The other good example of the advantage to use ZAKGEAR methodology is Ultra Globoid Gear development which was conducted in 2001 under a contract with New Venture Gear. While the practical test results of the novel Ultra Globoid Gear design has not been disclosed, ZAKGEAR was the primary supplier of the design and analyses software, which made it possible production and validation of the gear.
MAXTORQUE high-performance valve products include self-locking worm-gear solutions that reduce your workload to operate a valve by 75%. This improves your HSE profile and worker efficiency on manual valves and smaller actuators on motorized valves.
Enables quick, fully automated measurement of tooth profile, lead, pitch and run out of various gears and worm gears used for precision instrument, precision machines, and vehicle mounted electronic devices. Enables highly reliable and accurate data measurement from gear lead measurement to data analysis. Facilitates comparison of gears with JIS standard, demonstrating its value in worm gear precision analysis and quality control.
Rapidly measures gear meshing precision based on JGMA standards. Also capable of measuring meshing error between a worm gear and worm wheel. Supports quality assurance of meshing precision which is an important quality element for gears.
Romax Enduro offers further methods for a more flexible and detailed gear design process, such as batch running (enabling design and optimisation of multiple gear sets simultaneously), parametric studies, tolerancing and sensitivity studies, and the ability to add further detail such as micro-geometry.
In this webinar we present a powerful combination of tools for gear design throughout the development process: from early stage design indication in Romax Concept through to advanced, parametric and flexible system modelling in Romax Enduro.
Gear Generator is a tool for creating involute spur gears and download them in DXF or SVG format. In addition it let you compose full gear layouts with connetcted gears to design multiple gears system with control of the input/output ratio and rotation speed. Gears can be animated with various speed to demonstrate working mechanism.
Pinion of the presented gear set has an involute geometry. It can be manufacturing by different methods including but not limited by thread grinning, milling, hobbing, rolling and whirling. Manufacturing of the face gear is more complex, but it can be done on a regular hobbing machine with manor adjustments. The hob cutter has to have similar to the pinion form. Localization of the contact pattern can be done by different methods: gear cutter modification, pinion cutter modification or adjustment of the pinion cutting tool pass. It is a mistake to use an oversized gear cutter for localization of the contact pattern. Normally the oversized cutters are proposed by gear cutting shops as a simple way to localize the contact pattern and decrease sensitivity of the gear set for misalignments. The author had experience with different suppliers that used oversized cutters to cut the gears. Every time computer simulation showed incorrect location of the contact. Normally the supplier conducts a rolling test of the gear set to show the tooth contact. But it is always very difficult to see the contact area on a face gear with small teeth. Transmission error is normally very small and the gear set is very quiet even with incorrect contact because of a large number of the teeth participate in the contact in the same time. The worm face gear drive has many advantages like higher efficiency, lower noise, higher strength and more. In most of the situations even poor manufacturing worm face gear set will be working as good or a little better than a regular worm gear set. But in applications with high requirements the design and manufacturing has to be done with correct understanding of the geometry of the gear set. Computerized 3-dimentional of the geometry and the contact would be the best currently available tool for that.
The backlash can be adjusted only on tapered pinion by moving the pinion along its axis. Only axial motion of the pinion does not change the contact pattern. Adjustment of the backlash on gears with cylindrical pinion is impossible without braking the contact. Normally the backlash on the worm face gear can not be better than on a regular worm gear. A designer should not use a worm face gear because of possible low backlash. The worm face gear will always have a higher run out than a regular worm gear. The run out and the profile angle normally determine required amount of the backlash. Higher profile angle and higher run out need higher backlash. Unfortunately the profile angle on the worm face gear can not be small because of undercuts. Small profile angle on the pinion will make an undercut on the front flank of the pinion. A small profile angle on the backside of the pinion will generate an undercut on the gear tooth. The benefit of the regular worm gear is possibility to use a small profile angle. It is even possible to make a worm gear with 0-pressure angle.
The ratios are limited because of the realistic pinion would have 1,2 or 3 threads. The problem is the gear cutter. The gear cutter has to have the same geometry that the pinion so it has to have the same number of the threads. Unlike manufacturing of worm gears an oversized cutter can not be used. This fact was tested a number of time by the author on 3-dimentional computerized models of the gears. The cutter has a limit in its lead angle (some 25 degrees) so the pinion has the same limit. Hunting ratio is very desirable during the gear cutting for decreasing spacing error. In our case it is very important because the small and flexible cutting tool. The hunting ratio can be achieved only with 1 or 3 thread cutter. So good gear set ratio can be for example: 44:3 or 67:3 but not 66:3 or 72:3.
The molding process is as easy as molding of hypod, HRH, crown or spiral bevel gears. Unfortunately the gear manufactures can not provide the computer models of the gears. It does not allow designing a mold correctly. Plastic shrinks. It has to be taken in to account. Using oversized gear and pinion as electrodes do not solve the problem because it is impossible to cut the gear that is oversized in the same directions those plastic shrinks. 3D cad models have to be used for mold design and inspection. CAD model can be created from a master par by mapping on CMM. However such of model has low accuracy. Advanced computerized 3-dimentional tools have to be used to create 3D CAD files of the theoretical gears.
The gears almost always have two different pressure angles on the same tooth. The front working angle is usually about 10 and rear angle is 30 degrees. Different pressure angles are not a very good solution for the drive that has to rotate in both directions. However it is possible to design and manufacture the worm face gear with equal profile angle with an extensive help of the advanced computerized 3-d CAD tool.
The AE1000 Weatherproof Series version is the next generation of our antenna Positioners. With a fully sealed cover and connection points, the unit has been designed for harsh environments. Optional heaters can be installed for deployments in the worst case scenario down to -40C. The AE1000 Weatherproof Series version is perfect for Phased Arrays and can be adapted to your specific requirements. Single worm gear drive train with adjustments gives smooth powerful movement with less than .03 system backlash. The physical limit switches on each axis can be adjusted for any spectrum of use. Rack-Mount controller packages include the (RC2800PRKX2SU) control unit providing features such as ramp up or ramp down, speed control, limit switches for reference return and reverse delay can all be adjusted to maximize the performance of your system. Custom designs can be configured for your Dish feed and or Dish including feed attachment arms, or we can supply our custom built Septum Feeds for your (S-Band) or (L-Band) or our New Multi-Frequency Dish Feeds. For small phased arrays, we can provide a complete Turnkey System including cross boom, vertical risers and complete (Linear), (Circular) or (Helical) systems to meet your requirement. When it comes to the movement of your small to mid-sized antenna system, contact M2 to help configure your next system. 2ff7e9595c
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