Category Archives: Ball Screw Products

Calculating Ball Screw Rigidity

Design World is a great resource for industry news, white papers, calculators and many other essential tools for design engineers. Recently, Design World published a formula which can be used to determine the rigidity of a ball screw.

Rigidity is an essential characteristic in ball screw selection.  It can be defined as the amount of elastic deformation the ball screw will experience in the axial direction under a given load. This is important, because elastic deformation affects the positioning accuracy of the system.

To read the full article and view the equation for calculating ball screw rigidity, click here.

Integral Safety Threads

Ball nuts can fail for a variety of reasons. Primarily, it’s fatigue of the bearing balls or the threaded surface, which is why proper lubrication (link to lube blog post) is so important. However, ball nuts can fail prematurely due to misalignment, impact loading, contamination, or external damage to the return circuits. Premature failure may result in the loss of some or all of the balls between the nut and screw. When all the balls are lost the nut is no longer engaged with the screw and therefore may not move when the screw is rotated or, in vertical applications, will free fall along the screw.

In applications where this loss of ball type failure could result in injury or death, this failure needs to be considered in the design. Possible preventative measures include the use of two or more screws supporting the load, use of nuts with multiple independent ball recirculation circuits, use of Ball Deflectors which prevent the balls from exiting the ball nut out the ends.

There is one more preventative measure that has proven itself in testing and in practical use; Integral Safety Threads. These unique solutions that provide the ball nut with a secondary safety thread – a reverse thread in the nut body itself. This special thread extends from the ID (Internal Diameter) of the nut to below the OD (Outside Diameter) of the screw without making contact. In the unlikely event that all the balls in the nut are lost, this “safety” thread will engage the screw and prevent free-fall. Although this thread can be used to lower the load to a safe position, it is not to be used otherwise. This can also be accomplished with the use of a special flange if the ball nut body cannot accommodate the Safety Thread feature.

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Design Considerations for Ball Screw Safety

There are several factors conducive to a ball nut failing prematurely, such as misalignment, impact loading, a lack of lubrication, contamination or external damage to the return circuits. However, the primary failure mode for ball nuts is fatigue of the bearing balls or thread surface. Premature failure may result in the loss of some or all of the balls between the nut and screw. When all the balls are lost, the nut is no longer engaged with the screw and therefore may not move when the screw is rotated or, in vertical applications, will free fall along the screw.

In applications where this loss of ball type failure could result in injury or death, this failure needs to be considered in the design. Possible preventative measures include the use of two or more screws supporting the load, use of nuts with multiple independent ball recirculation circuits, use of ball deflectors which prevent the balls from exiting the ball nut out the ends  or use of industry-leading integral safety thread ball nuts.

The integral safety thread is a unique solution that provides the ball nut with a secondary safety thread– a reverse thread in the nut body itself. This special thread extends from the ID of the nut to below the OD of the screw without making contact. In the unlikely event that all the balls in the nut are lost, this safety thread will engage the screw and prevent free fall.

Although this thread can be used to lower the load to a safe position, it is not to be used otherwise. This can also be accomplished with the use of a special flange if the ball nut body cannot accommodate the safety thread feature.

Ball safety

Three Popular Screw Types Defined

When considering the vast majority of applications in which machine screws are used, it’s important to review the functions of some of the major types of screws. Below, we’ll take a look at the designs, functions and more while we define acme, ball and planetary screws.

Acme Screws:

Acme

The acme screw thread, sometimes referred to as the trapezoidal thread, is used for lead screws. They are often needed for large loads, or when the environment is less than desirable.

The acme thread form has been around for over a century, replacing square thread screws which had straight-sided flanks and were difficult to manufacture.

There are two main classes of acme thread forms: general purpose (G) and centralizing (C). The general purpose and centralizing thread forms have a nominal depth of thread of 0.50 x pitch and have a 29 degree included thread angle, which has allowed companies to develop unique screw diameters and leads. European metric Trapezoidal thread forms have a 30 degree Included thread angle.

When compared to general-purpose thread forms, centralizing threads are manufactured with tighter tolerances and reduced clearance on the major diameter. For instance; If an acme nut is side loaded with a radial load, a “G” class will wedge when the nut thread flanks come in contact with the screw thread flanks. To prevent this wedging, a “C” class thread form can be used, since it utilizes less clearance and tighter tolerances are allowed between the major diameter of the nut and the major diameter of the screw.

Industry leaders have developed several unique thread forms, such as stub acme forms and 40 degree included angle, which allow them to provide a variety of diameter and lead combinations.

Ball Screws:

ball

For loads requiring a greater amount of efficiency, companies often turn to ball screws. A ball screw assembly is a device comprised of a nut, screw, and reciprocating ball bearings. The bearings provide the thread engagement between the nut and screw.

Ball screws offer an efficient means for converting rotary motion to linear motion. A ball screw is an improvement over an acme screw just as an anti-friction ball bearing is an improvement over a plain bushing.

In the long run, ball screw systems can prove to be a cost-effective alternative to pneumatic or hydraulic systems, which require constant electrical and air power.

Planetary Roller Screws:

Planetary

Planetary roller screws are remarkable devices designed to convert rotary motion into axial force or vice versa.

The planetary roller screw design offers multiple advantages and reliability for the most demanding applications when compared with other lead screw types due to its rolling motion. These screws offer high efficiency even in relatively shallow lead designs.

The multitude of contact points can carry large loads and provide very high resolution (small axial movement) when using very shallow leads. Planetary roller screws produce high rotational speeds with faster acceleration without adverse effects.

Helpful Formulas for Calculating Ball Screw Life Expectancy

Due to their steel-on-steel design, the bearing industry has developed ways to calculate the life expectancy of ball screws. However, other factors, such as contamination, lubrication and improper mounting and installation techniques, can also lessen the life of a ball screw. For manufacturers hoping to extend the life of their screws, it can be beneficial to order a larger size screw to handle a larger load, prolonging the life of the screw.

For applications where the loads and/or rotational speed vary significantly, an equivalent load can be calculated using the following formula:

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The life required in revolutions is determined by multiplying the total stroke in millimeters by the total number of strokes required for the designed life of the equipment and then dividing by the lead of the ball nut. Ball nut life is greatly influenced by the operating condition, including speed and vibration the assembly may see. A fatigue factor must be considered when calculating life. To calculate the life for a ball nut use the following formula:

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Formula3

 

 

Indirect vibration is any vibration associated near the screw mounting which influences the stability of the assembly. Direct vibration pertains to any vibration directly linked to the screw assembly which influences the stability of the assembly. High cyclical impact is any repetitive impact or high deceleration of the ball screw assembly.

If operation reliability higher than 90 percent is required, then the theoretical life must be corrected by using a reliability factor according to the table.

Formula4

If total time is needed, the following equation can be used to find the life measured in hours:

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Instead of hand calculations, here are some charts to help calculate life expectancy:

Metric:

Inch: