Modified worm gear hobbing for symmetric longitudinal crowning in high lead cylindrical worm gear drives

Abstract A single enveloping worm gear of cylindrical worm gear drive is cut by an oversized hob. The oversize provides a longitudinal crowning on the worm gear tooth surface. However, when a lead angle of the worm becomes higher, the longitudinal crowning becomes more asymmetric. The asymmetrically crowned worm gear surface makes the gear contact more sensitive to the certain direction of misalignment. To change the longitudinal crowning from asymmetric to symmetric, a method of modified worm gear hobbing is proposed. The modification uses a modified machine tool setting and a modified hob specification. A new hobbing mechanism or hob geometry is not required in this method. Results of the proposed modification are confirmed by using a surface separation topology based on differential geometry, and contact pressure analysis based on finite element method.