Bevel Gears

• The elements of the teeth of the straight bevel gears are straight lines which converge in
to a common apex point.
• Involute profile.
• straight bevel gears are easy to design and manufacture.
• Create noise at high speed application.
• Spiral bevel gears are difficult to design and manufacture.
• Specialized and sophisticated machinery is required.
• Have smooth engagement of teeth which results in quite operation, even at high speeds.
 Different Types Of Bevel Gears

• Classified on the basis of pitch angle

• External bevel gear
When pitch angle (angle between
pitch line and axis of gear) is less
than 90°.
• Crown gear (pitch angle = 90°)
• Internal bevel gear
• Teeth are cut inside the pitch cone.
(pitch angle > 90°)
• Specific categories
Miter gear (90°)
 Terminology of Bevel Gear

• Pitch cone: Imaginary cone which contains the pitch line of all
teeth.
• Cone center: Apex of pitch cone.
• Cone Distance Ao: length of pitch cone element.
• Pitch angle: Angle that pitch line makes with the axis of the gear.
• Addendum angle α: Angle subtended by addendum at the cone
center.
• Dedendum Angle δ : Angle subtended by dedendum at the cone
center.
• Face angle: Angle subtended by the face of the tooth at the cone
center = pitch angle + addendum Angle
• Root angle: Angle subtended by the root of the tooth at the cone
center= pitch angle – dedendum angle
• Back cone: Imaginary cone and its elements are perpendicular to
the elements of the pitch cone.
• Back cone distance: length of back cone element
• The analysis for a bevel gear will
show that a true section of involute
profile lies on the surface of a
sphere.
• Tredgold’s approximation – a
tangent to the sphere at the pitch
point will closely approximate the
surface of gear tooth for a short
centre distance on either side of the
pitch point.
• Therefore, the back cone can be
developed as a plane surface for
constructing a spur gear.
• The tooth profile resemble those of
spur gears having pitch radii equal
to the developed back cone radii
(rb).
• The formative number of teeth is
given by,
′
2rb 𝐷
z = also z =
m 𝑚

• where, m is the module at the large

end of the tooth.

z′ 2rb
∴ =
z D

𝐴𝐵 𝐷Τ2
• From geometry, cos 𝛾 = =
𝑟𝑏 𝑟𝑏
𝑧
•∴ 𝑧′ =
cos 𝛾
• Now, consider ∆ OAB,
𝐴𝐵 𝐷𝑝 /2 𝑚 .𝑧𝑝
tan 𝛾 = = =
𝑂𝐵 𝐷𝑔 /2 𝑚 .𝑧𝑔

𝑧𝑝
∴ tan 𝛾 =
𝑧𝑔

𝑧𝑔
• Similarly, tan Γ =
𝑧𝑝

𝜋
• Also, 𝛾 + Γ =
2

• The cone distance A0 is given by,

𝐴0 = 𝑂𝐴 = 𝐴𝐵 2 + 𝑂𝐵 2

𝐷𝑝 2 𝐷𝑔 2
= +
2 2
Force Analysis
Force Analysis

(a) The thrust component on the pinion is

equal and opposite of the radial component
on the gear.
(b) The thrust component on the gear is
equal and opposite of the radial component
on the pinion.

The tendency of thrust components is to

separate the meshing teeth. This fact is
useful in deciding their directions.
 Force Analysis
• The radial component on the gear is
equal to the axial component (Pa) of
the pinion. (827.54 N)

• The axial component on the gear is

equal to the radial of the pinion
(1103.38 N)
 Beam strength of bevel gear

• Formative gear at the large end in a plane perpendicular to tooth element.

• Consider an elemental section of the tooth at a distance ‘x’ from the apex ‘o’ and having width dx.
• From Lewis equation, at a distance x from apex
𝛿 𝑆𝑏 = 𝑚𝑥 𝑏𝑥 𝜎𝑏 𝑌 ________(a)
where, 𝛿 𝑆𝑏 = beam strength of the elemental section (N)
𝑚𝑥 = module of the section (mm)
𝑏𝑥 = face width (mm)
Y = Lewis form factor based on the virtual no. of teeth
• From figure,
𝑟𝑥 𝑥 𝑥.𝑅
= ∴ 𝑟𝑥 = ______(b)
𝑅 𝐴0 𝐴0
• At the elemental section,
2𝑟𝑥 2𝑥𝑅
𝑚𝑥 = = ______(c)
𝑧 𝑧𝐴0
• At the large end of the tooth,
2𝑅
𝑚= ________(d)
𝑧
𝑥
• From (c) and (d), 𝑚𝑥 = 𝑚 _____(e)
𝐴0
• Also, 𝑏𝑥 = 𝑑𝑥 _______(𝑓)
• Substituting (e) and (f) in (a),
𝑚 𝜎𝑏 𝑌 𝑥 𝑑𝑥
∴ 𝛿 𝑆𝑏 =
𝐴0
𝑚 𝜎𝑏 𝑌 𝑥 𝑑𝑥
𝑟𝑥 . 𝛿 𝑆𝑏 = . 𝑟𝑥
𝐴0
• From (b) and (g),
𝑚𝜎𝑏 𝑌𝑅
‫ 𝑥𝑟 ׬‬. 𝛿 𝑆𝑏 =
𝐴0 2
‫ 𝑥 ׬‬2 𝑑𝑥
• The left hand side indicates the torque Mt ,
𝑚𝜎𝑏 𝑌𝑅 𝐴0
∴ 𝑀𝑡 = ‫𝐴׬‬ 𝑥 2 𝑑𝑥
𝐴0 2 0 −𝑏
𝐴
𝑚𝜎𝑏 𝑌𝑅 𝑥3 0
=
𝐴0 2 3 𝐴 −𝑏
0
𝑏 𝑏2
= 𝑚 𝑏 𝜎𝑏 𝑌𝑅 1 − +
𝐴0 3𝐴0 2
• Assuming beam strength as the tangential force at the large end of tooth,
 𝑀𝑡 = 𝑆𝑏 . 𝑅
𝑏
∴ 𝑆𝑏 = 𝑚 𝑏 𝜎𝑏 𝑌 1 −
𝐴0
𝑏
• The term 1 − is called the bevel factor.
𝐴0
10𝑚
• Face width, b = 𝐴0 ቋ whichever is smaller.
3
 Wear strength of bevel gear

• Applying Buckingham’s equation to formative gears,

𝑆𝑤 = 𝑏 𝑄 𝑑𝑝′ 𝑘 ______(a)
• Where, b = face width of gears (mm)
Q = ratio factor
𝑑𝑝′ = pitch circle diameter of formative pinion (mm)
k = material constant (N/mm2)
• The pitch circle diameter of formative pinion,
𝐷
𝑑𝑝′ = 2𝑟𝑏 also 𝑟𝑏 = 𝐴𝐵 𝐷 Τ2
2 cos 𝛾 From geometry, cos 𝛾 = =
𝐷𝑝 𝑟𝑏 𝑟𝑏
∴ 𝑑𝑝′ = _____(b)
cos 𝛾
• Where, 𝐷𝑝 is the pitch circle diameter of the pinion at the large end of the tooth.
• From (a) and (b),
𝑏 𝑄 𝐷𝑝 𝑘
𝑆𝑤 =
cos 𝛾
0.75 𝑏 𝑄 𝐷𝑝 𝑘
∴ 𝑆𝑤 =
cos 𝛾
• The ratio factor (Q),
2 𝑧𝑔′
𝑄=
𝑧𝑔′ + 𝑧𝑝′
𝑧𝑝 𝑧𝑔 𝑧𝑔
• Where, 𝑧𝑝′ = and 𝑧𝑔′ = =
cos 𝛾 cos 90°−𝛾 sin 𝛾
2𝑧𝑔
∴𝑄=
𝑧𝑔 +𝑧𝑝 tan 𝛾

• The material constant k is the same as for spur gears and is given by,
1 1
𝜎𝑐 2 sin 𝛼 cos 𝛼 𝐸 +𝐸
𝑝 𝑔
𝑘=
1.4
𝐵𝐻𝑁 2
= 0.16
100
 Effective Load on Gear Tooth
• The tangential component due to power transmission is determined by,
60×106 𝐾𝑤
𝑀𝑡 =
2 𝜋 𝑛𝑝
2 𝑀𝑡
𝑃𝑡 =
𝐷
• The effective load (𝑃𝑒𝑓𝑓 ) between two meshing teeth is given by,
𝐶𝑠 𝑃𝑡
𝑃𝑒𝑓𝑓 =
𝐶𝑣
• Where 𝐶𝑠 = service factor
𝐶𝑣 = velocity factor
6
• The velocity factor, 𝐶𝑣 = (for cut teeth)
6+𝑣
5.6
𝐶𝑣 = (for generated teeth)
5.6+ 𝑣
• Where v is the pitch line velocity (m/s).
• The equation for dynamic load in bevel gears is,
21𝑣 (𝐶𝑒𝑏 + 𝑃𝑡 )
𝑃𝑑 =
21𝑣+ 𝐶𝑒𝑏+ 𝑃𝑡

• Maximum expected error between two meshing teeth (mm),

Module Class - 1 Class - 2 Class – 3 Manufacturing methods:

(mm)
Class – 1well cut commercial gear teeth
Up to 4 0.050 0.025 0.0125
Class – 2 gear teeth cut with great care
5 0.056 0.025 0.0125
Class – 3 ground and lapped precision
6 0.064 0.030 0.0150
gear teeth
7 0.072 0.035 0.0170
8 0.080 0.038 0.0190
9 0.085 0.041 0.0205
10 0.090 0.044 0.0220

• The effective load is given by, 𝑃𝑒𝑓𝑓 = 𝐶𝑠 𝑃𝑡 + 𝑃𝑑

• To avoid failure of the gear tooth due to bending, 𝑆𝑏 = 𝑃𝑒𝑓𝑓 𝑓𝑠
• To avoid failure of the gear tooth due to pitting, 𝑆𝑤 = 𝑃𝑒𝑓𝑓 𝑓𝑠