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The mating gear would be ferritic nitro carburized, so it would have a very hard wear surface. My main concern is the wear characteristics of the soft part against this hard gear. If this is going to be a problem, no matter the material, we'll need to heat treat the pinion.

Is there ever a case where using annealed 4140 without heat treatment (185-225 BHN) would work for the pinion of a gear set if the stresses are low enough? (12 ksi beam stress, 42 ksi contact, 60 rpm, 2 inch pitch Ø)

I'm wondering if anyone has experience with using 8620 (carburized or not)as a worm gear material. I know that the worm itself is usually made from steel but can the gear be made from something other than ductile iron or bronze?

Essentially I am looking for a method of translating a shaft similar to the helical rack that you're describing. The worm would function the same way it does in conventional applications, but the wheel would be replaced by a rack. The reason that I was wondering about a worm was because I...

I'm wondering if worm gears are ever used to produce translation rather than rotation. In other words, can the teeth that would normally be hobbed onto a wheel be cut onto the length of a shaft.