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why does an electric knife have a nylon gear and a steel worm?
All the previous answers miss the salient reason for the design engineer's choice of materials.The worm is usually of a small diameter, but designer often wishes the knife to able cut in arduous situations [though frozen meat for example] the loading imposed on a small diameter nylon worm gear would cause elevated wear rates and hence failure of the drive very quickly. Steel is a cheap and strong, always the production engineer's favourite choice, minimising cost and maximising profit.
The driven gear is of a much larger diameter and the loading it experiences is less. The design engineer must consider the safety of the user of the knife and in this case he is worried about what would happen to the knife and its user if the knife blades where to jam. So for safety he chooses to use nylon [ or possibly PTFE, Tufnol or similar materials, even wood in some cases ] so that in a jam fault situation, the loading exceeds the maximum designed working load and the gear teeth strip protecting the user from kickback or injury from the knife. This also prevents the electric motor from overheating as the motor is now allowed to free run.
On the better quality and usually more expensive knives there is usually also thermal fuse close to the motor in the power supply line, such that if the motor overheats under fault conditions the fuse blows and the power is removed from the motor.
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