Finite element analysis of composite worm gears

Worm gears are commonly used in windshield wipers and power windows of automobiles. The goal of this work is to study several material problems, such as production bottlenecks and excessive scrap, resulting from the production of steel worm shafts. A possible solution is explored in this work by characterizing material properties of a promising candidate (glass reinforced acetal copolymer) that can replace steel in worm gears. Finite element analysis of the worm thread under static loading and constant temperature is performed in order to calculate the size of the new composite part. The results obtained in this work support the possibility of manufacturing composite worm shafts that could operate at elevated temperatures without sacrificing part performance, while reducing part weight leading to improved fuel economy, noise reduction, and manufacturing problems associated with the steel part. The finite element analysis shows that compared to a steel gear, the axial pitch of a composite worm gear must be increased by 250% in order for it to operate without failure for 10 years at a constant temperature of 23 degrees C. This increase in the axial pitch would ramp up to 400%, if the composite worm gear is expected to operate for 10 years at a constant temperature of 100 degrees C.