Data Sheet 1_Development of an empirical regression model for predicting worm gear efficiency.pdf

This study develops a constrained empirical modelling and optimisation methodology for an industrial single-start worm gearbox used in a continuous-duty soot-blower application. The input speed (342 rpm), centre distance and operating requirements are fixed, while the worm module and worm-wheel tooth count are varied over a manufacturable design space.

Thirty-five design combinations are evaluated analytically, followed by local regression modelling and multi-criteria selection. To avoid kinematic redundancy, the revised regression uses module and worm-wheel tooth count as predictors because output speed is deterministically related to tooth count under fixed input speed. The selected configuration, m = 2.75 mm and Z₂ = 43, gives a calculated efficiency of 74.6%, compared with 68.8% for the existing m = 2.54 mm, Z₂ = 45 design.