Worm Gear

Features & Benefits

• High single-stage reduction ratios
  Worm gears can deliver large reduction ratios (commonly 20:1–60:1 and up to about 100:1) with just one gear pair, avoiding multi-stage gear trains and keeping the drive compact.

• Self-locking and load-holding capability
  When the friction angle exceeds the worm lead angle, the worm wheel cannot back-drive the worm, giving a built-in braking effect that keeps loads in place when power is off – valuable in lifts, hoists, gates and actuators.

• Compact, smooth and quiet operation
  The right-angle layout and continuous sliding contact allow compact housings with smooth motion and low noise, which is attractive for many industrial, automation and handling systems.

• Optimized material pairing for sliding contact
  A hardened steel worm paired with a bronze or brass worm wheel combines high strength with good lubricity and wear resistance; bronze alloys are widely used for worm wheels because they provide a durable running surface under sliding contact.

• Custom small-module precision gearing
  DD Gear focuses on small-module gears. We control worm lead, flank profile and worm-wheel tooth geometry to the accuracy levels defined in ISO / DIN standards for worm gears, supporting precise motion in compact automation and robotics equipment.

• Balanced design for efficiency and life
  While worm gears can have lower efficiency than spur or helical gears, careful design of lead, materials, lubrication and surface finish can keep efficiency in the roughly 50–90% range, depending on ratio and operating conditions. DD Gear works with customers to balance ratio, self-locking needs, heat generation and service life.

Technical Specifications

Final values will be defined according to your drawings and performance requirements.

Applications

• Lifts, hoists and winches
  High ratio and self-locking properties help hold vertical loads safely when power is removed.

• Conveyors and material-handling equipment
  Compact worm gearmotors drive conveyors, screw feeders and indexing mechanisms where space is limited and quiet running is important.

• Valve and rotary actuators
  Worm gears in manual or motorized actuators provide fine control and hold position in industrial valves and dampers.

• Automotive steering and adjustment systems
  Automotive steering, seat and mirror adjustment mechanisms use worm gears for compact packaging and inherent self-locking.

• Robotics, automation and positioning tables
  Worm drives in turntables, rotary indexing tables and positioning stages support smooth, quiet motion with moderate backlash and high holding torque.

Gear Manufacturing Process

Every custom worm gear is produced under a controlled gear manufacturing route designed for precision and durability. A typical process flow is:

1. Forging or bar cutting of shaft blanks

2. Lathe machining of shaft diameters and reference surfaces

3. Hobbing or shaping of gear teeth

4. Drilling, milling, and other CNC machining operations

5. Heat treatment (such as carburizing, quenching, tempering, nitriding)

6. Shot blasting and stress relief as required

7. Finish machining and grinding of journals and critical surfaces

8. Gear grinding (profile or worm grinding) where accuracy demands it

9. Cleaning and rust prevention treatment

10. Final inspection and packaging for shipment

Precision Gear Customization Process

DD Gear follows a clear, eight-step customization process:

Step 1 – Requirement Collection
Customers provide design requirements, 2D drawings, 3D models, or physical samples, together with basic duty cycle information (torque, speed, life, installation).

Step 2 – Drawing Design & Optimization
Based on the provided drawings or samples, DD Gear prepares or optimizes detailed manufacturing drawings and shares them with the customer for confirmation.

Step 3 – Quotation
After the drawings and technical points are confirmed, we issue a precise quotation covering tooling, piece price, lead time, and quality requirements.

Step 4 – Tooling & Fixture Preparation
Once the price is confirmed, we arrange tooling and fixture production. Any tooling cost is agreed with the customer in advance and can be offset or refunded after mass orders, according to the commercial agreement.

Step 5 – First Sample Approval
After tooling and fixtures are ready, we manufacture the first sample batch—typically within about 30 days—and ship it to the customer for testing.The customer inspects and validates the samples in their gearbox or test bench and provides feedback on dimensions, performance, and any required adjustments.

Step 6 – Mass Production
When the sample is approved, we start mass production according to the agreed production plan and quality standards.

Step 7 – Finished Product Inspection
After production, we inspect hardness, dimensions, runout, tooth accuracy, and other critical characteristics to ensure full compliance with the drawing and standards.

Step 8 – Shipping Arrangement
Once inspection is passed and shipment is approved by the customer, we arrange booking, packaging, and delivery to the specified destination.

Quality Assurance & Inspection

DD Gear applies the same quality philosophy to all precision gears:

• Quality management systems based on ISO 9001 and IATF 16949

• Process control from incoming material to final inspection, including:

  • Material certification and chemical composition checks

  • Hardness and case depth verification after heat treatment

  • Gear measurement for profile, lead, pitch, and runout

  • Surface roughness testing on gear flanks and journals

  • Dimensional inspection with calibrated gauges and CMMs

• Traceability for each batch with inspection records and reports

• Optional documentation such as PPAP/FAIR packs on request

Packaging

Usage & Installation Notes

• Ensure worm and wheel are installed with the specified center distance and alignment to achieve the correct contact pattern and backlash.

• Use the recommended lubricant type and viscosity (often specific worm-gear oils with EP and anti-wear additives) and maintain oil level; poor lubrication will accelerate wear and reduce efficiency.

• Consider heat dissipation in high-ratio or high-duty applications; worm drives can generate more heat than spur/helical gears due to sliding contact.

• Avoid exceeding rated torque or speed and minimize repetitive shock loading, which accelerates tooth and bearing fatigue.

• During maintenance, inspect bronze wheel teeth for pitting, scoring or wear and check for increasing backlash or noise as early indicators of degradation.

Company Strength – DD Gear

• Specialized in small module, high-precision gears and shafts for EVs, humanoid robots, AGVs, and intelligent automation.

• Integrated manufacturing from forging and machining to heat treatment and gear grinding.

• Quality systems aligned with automotive standards, with experience supporting OEM and Tier 1 projects.

• Engineering support covering concept feasibility, DFM reviews, and failure analysis feedback.

• Global export capability with experience serving customers in multiple countries.

Q1: What information do you need for a worm gear quotation?
We normally need 2D drawings (PDF) and, if available, 3D models; target ratio and direction of rotation; material and heat-treat preferences; duty-cycle data (torque, speed, hours); self-locking or back-drivability requirements; and expected annual volume.

Q2: Do you supply complete worm gearboxes or only gear sets?
DD Gear primarily supplies worm and worm wheel components and related shafts/housings according to drawings. Complete gearboxes, motors and housings are usually assembled by our customers or their system partners.

Q3: Can you design for self-locking or for higher efficiency?
Yes. Self-locking depends on lead angle, friction and materials. We can help you choose geometry and material pairings to favor either stronger self-locking or higher efficiency, depending on your safety and energy-loss priorities.

Q4: What accuracy levels can you achieve on worm gears?
We manufacture worms and worm wheels to accuracy grades defined in DIN 3974 and related ISO guidelines, combined with general gear accuracy standards. Target grade is agreed with you according to backlash, noise and cost targets.

Q5: How efficient will my worm gear be?
Typical worm-gear efficiencies range roughly from 50–90%, with higher ratios usually reducing efficiency. Proper lubrication, material selection and surface finish are important to achieve the higher end of this range.