Worm Shaft Taper Geometry to Suppress Gear-Cutting Burrs
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Solution Overview
Problem
The existing worm shaft manufacturing process is prone to forming burrs at the tapered portion, leading to increased manufacturing costs due to the need for additional processing to remove these burrs, which complicates the assembly and operation of worm speed reducers.
Innovation Solution
The worm shaft design includes a tapered portion with a gradually increasing diameter and a main body portion where the gear portion is formed, with the bottom land of the gear positioned radially outer to the rotation axis, allowing for effective gear-cutting processing that suppresses burr formation and simplifies assembly, while maintaining sufficient gear length for proper engagement with the worm wheel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the gear portion is formed up to the tapered portion to enable assembly, then the assembly is enabled, but burrs are formed in the tapered portion increasing manufacturing cost
Solution Approach 1:
The gear portion is designed to end before the tapered portion in the preliminary design stage, preventing burr formation during gear-cutting processing while still enabling assembly through proper positioning of the insertion portion and wall surface
2Length of moving object
If the gear portion is formed up to the tapered portion, then the gear length is increased, but burr removal processing is required increasing manufacturing complexity
Solution Approach 1:
The gear portion is preliminarily designed to terminate before the tapered portion, eliminating the need for subsequent burr removal processing while maintaining sufficient gear engagement length for proper assembly
Data Source
AI summary
A worm shaft includes: an insertion portion; a wall surface; a tapered portion; and a main body portion, the gear portion is formed on the main body portion and the tapered portion such that a bottom land of the gear portion is positioned at radially outer side of a line extending in parallel with a rotation center axis of the worm shaft and passing through a boundary between the wall surface and the tapered portion.