Exit

Archive: Sep 2018

How to Make Bronze for Worm Gear Applications

Leave a Comment

A worm gear is a mechanical arrangement consisting of a spiral-threaded shaft butted against a toothed wheel, resembling a standard spur gear. The threaded shaft, also known as a worm, acts as the driving element, imparting motion to the wheel as the rotational power from the worm is transferred in a 90o plane.

Worm gears are typically used for their high gear reduction ratios. It is common for standard worm gears to achieve reduction ratios ranging from 20:1 up to 300:1. This attribute makes worm gears ideal for applications that require reduced rotational speeds or significantly increased torque. By comparison, it would take multiple conventional gearsets to achieve the same levels of reduction.

Worm gears also have another useful characteristic—they possess a natural self-locking feature by design. The worm can easily turn the gear wheel, but the gear wheel cannot turn the worm, thus preventing reverse movement.

 

How to Make Bronze

Bronze is one of the most commonly used alloys for worm gears due to the material’s desirable mechanical properties. The term “bronze” covers many copper alloys, though the final product ultimately depends on the other material contained within the alloy. For example, using nickel creates copper-nickel alloys, or using zinc creates brass. Bronze, on the other hand, is most often created by creating a copper alloy with tin or aluminum.

At Accurate Specialties, we utilize a variety of alloys to meet our client’s specific requirements. Typically, for worm gears, we recommend tin bronze (C91700) and aluminum bronze (C95400 and C95500) due to their relatively high strength, and superior fatigue, friction, and wear resistance.

The process of making bronze involves first heating the copper element to a specified temperature. Once the copper reaches a molten state, predetermined amounts of alloying compounds (such as aluminum or tin) are added to the molten copper. The molten alloy mix is then poured into molds for the gear components and allowed to cool.

 

Typical Bronze Worm Gear Applications

The high torque output of worm gears makes them suitable for heavily loaded machinery. Some of the most common applications for worm gears include:

  • Movable bridge components

The controlled and powerful motion of worm gears are ideal for inducing movements in large and heavy bridge structures.

  • Elevators, lifts, packaging equipment, and conveyors

Worm gears are used to provide the torque needed to transport heavy loads from one point to another. The non-reversible properties of this gear also act as a secondary safety braking system.

  • Heavy-duty construction equipment and trucks

Heavy vehicles often use a worm gear differential for additional power. Depending on the action of the vehicle, different amounts of torque may need to be delivered to each wheel. Worm gears are used to provide the necessary torque that governs each wheel’s performance.

 

Learn More

At Accurate Specialties Inc., we provide custom worm gear manufacturing services for numerous applications in almost any industry. Our technical team will work with you to help determine the best alloy for your unique specifications.

If you would like to learn more about how to make bronze, bronze worm gears, or any of our other products and services, feel free to contact us or request a quote.

Applications for Bronze Alloys

Leave a Comment

At Accurate Specialties, Inc. (ASI) we work to satisfy our customer requests and design specifications using optimal alloys to cast a wide range of bronze gears and composite gears for a comprehensive array of applications. We work with numerous bronze alloys, each delivering desired advantages for particular operations. Our expertise guides clients in selecting the best bronze alloy for their needs.

 

The Copper Development Association

The Copper Development Association (CDA) works to expand the copper market worldwide through its commitment to educating producers, fabricators, and end users regarding the benefits and uses for copper and copper alloys. With a commitment to helping copper businesses thrive, the CDA supports each application where copper plays a role.

 

Bronze Alloys and Their Applications

Accurate Specialties, Inc. offers a wide selection of bronze alloys to serve the varying needs of our clients. Various alloys can be created specifically to meet the needs of even the most unique or demanding applications. By consulting with each client, we will determine the best choice for your intended purpose or design. Some of the most common alloys we use include:

 

863 Manganese Bronze

Known for its high-strength and corrosion-resistance, this bronze alloy also features durability and longevity, making it an ideal option for heavy-duty applications such as construction and agricultural equipment. 863 Manganese Bronze is popular in bronze alloy applications such as:

  • Screw-down nuts
  • Load bearings
  • Bronze for gears
  • Cams
  • Gibs
  • Large stem valves
  • Bridge pins
  • Hydraulic cylinder components

 

907 Tin Bronze

This alloy offers quality corrosion resistance, especially in applications with seawater exposure. This bronze alloy is moderately machinable and performs well in wear and fatigue applications. 907 Tin Bronze is utilized in bronze alloy applications such as:

  • Bearings
  • Bushings
  • Bronze for gears
  • Piston rings
  • Pump components
  • Marine fittings

 

917 Tin Bronze

Typically selected for its increased load carrying capacity – especially heavy loads involving slow and irregular movement – this alloy is highly corrosion resistant and requires adequate lubrication.

917 Tin Bronze is commonly used for applications such as:

  • Bearings with slow speed and high load
  • Gears
  • Movable bridge components
  • Wheels in worm drives
  • Turntables for bridges

 

954 Aluminum Bronze

This extremely strong bronze alloy  features superior corrosion resistance. It is the most popular aluminum bronze alloy, selected for its exceptional elevated temperature strength, weldability, high tensile and yield strength, as well as ductility. 954 Aluminum Bronze is commonly used in bronze alloy applications such as:

  • Worms and worm gears (low speed/high strength)
  • Spur gears
  • Bushings
  • Bearings
  • Pickling (baskets/hooks)
  • Valve components

 

955 Aluminum Bronze

This alloy is among the toughest non-ferrous alloys available. It offers superior yield and compressive strength with high hardness and elongation. 955 Aluminum Bronze offers good corrosion resistance to seawater, as well as impressive heat resistance. It is weldable with good machinability. 955 Aluminum Bronze is found in applications including:

  • Bushings
  • Agitators
  • Landing gear components
  • Bronze for gears
  • Pickling (baskets/hooks)
  • Worms
  • Aircraft engine (seats, valve guides)

Bronze Alloys: Request a Quote

ASI is a leading North American manufacturer of blank gears. With our own bronze foundry and machine shop, we provide end-to-end fabrication services for a wide range of customer needs. We offer quick turnarounds, often delivering in only a week. Customers should note that ASI does not currently cast bronze alloys with high lead content (for example, 928, 932, and 943).

 

To learn more about ASI and our products and services, please request a quote or contact us.