Bevel Gear

Dr. Benedict Thomas

School of Mechanical Engineering
 Bevel Gears
• Bevel gears transmit power between two intersecting shafts at
any angle or between non-intersecting shafts. They are
classified as:

a) Straight bevel b) Zerol gear c) Spiral tooth bevel

d) Hypoid bevel gears.

 Classification of Bevel Gears
1. Based on shape of teeth:
 Straight teeth bevel gears and
 Curved teeth bevel gears, specified as spiral bevel gears.
2. Based on the angle between the shaft axes.
Shaft angle.
a) shaft angle is less than 90 – external gear
b) shaft angle is greater than 90– internal gear
c) shaft angle is 90- crown-gears (mating gear pitch angles is 45
degree)
d) Miter gears (when two identical bevel gear are mounted), both
mating gears pitch angles are 45 degree)
Classification of Bevel Gears
Bevel Gear Nomenclature
Bevel Gear Nomenclature
 Bevel Gear Terminology

7
Figure 1
Bevel Gear Nomenclature
 Virtual number of teeth
Similar to helical gears, in bevel gears also calculation are done based on
virtual number of teeth. The virtual number of teeth are defined is defined
as the number of teeth of an imaginary spur gear whose radius is equal to
back cone radius Rb and having pitch of the bevel gear.
2R
Z v  b here, Db  Pitch circle radius of imaginary spur gear=2Rb
m
For bevel gear, From figure 1.
r= pitch circle radius,
m=module
r
cos  
Rb
r mZ
So, Rb  
cos  2 cos 
2R 2mZ
Now, Z v  b 
m 2m cos 
Z
Zv 
cos 
 Determination of Pitch angle
n1 d 2 Z 2 r2
GearRatio  i  =  =
n2 d1 Z1 r1
  1   2 ,  2    1
From figure 1
r1 1
tan1   ,
r2 i
r2
tan 2   i
r1
b
Here, R 0  Mean cone distance from O=R 
2
R0   r1    r2   rv1 i 2  1
2 2

r2 r2 i
cos 1   
R0 rv i  1
2
i 2
1
1
 R0
rv1  Pitch radius of virtual spur pinion  R 0 tan 1 
i
rv2  Pitch radius of virtual spur gear  R 0 tan  2  R 0 i
av  Center distance of virtual spur gear=rv1  rv2
 1   i 2
1
av  R 0 1    R 0  
 i  i 
 b   i 2
1
av   R    
 2  i 
rv2
iv  Gear Ratio of virtual spur gear=  i2
rv1

i2  1 11
Let P be the tangential force, then
M t  M t v1
P 
r1 rv1
r1
rv1 cos 1 Mt Mt
 M t v1  Mt  Mt  
r1 r1 cos 1 i
i2  1
M t i2  1
 M t v1 
i 12
 Determination of Cone distance
In the the Hertz surface contact stress formula for spur gear,
substituting iv for i and av for a and [Mt]v for [M]t

 iv  1   iv  1 
 c  0.72     E [ M t ]v
 av   iv b 
Substituting the values
 
 
 i 2
 1   i 2
 1  [ M ] i 2
1
 c  0.72   E t
 b  i 1   i b 
2 2
i
 R   
  2   i  
3

c 
0.72   1
i 2 2
E [ M t ]   c 
 R  0.5b  2
ib 13
 Determination of Cone distance
Taking R/b=ψy and rearranging the previous equation, we get

2
  E [ M ]
R y i 2
 1 3 
0.72

t

  y  0.5b   c   i

The above equation is for external bevel gear. The values of

ψy for different applications are given in DDB.

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 Determination of Module
The module of the bevel gear can be obtained from the beam
strength equation of equivalent spur gear.
 iv  1  M t v
b 
av mv b yv
M t i2  1
We knowthat , iv  i 2 ,  M t v  ,
i
 b   i2  1 
av   R     and
 2  i 
 R  0.5b 
mv  mav cos   mt cos 
R
Substituting these value s in the above equation , we get :

 b   i  1
2 Mt  i2  1

i

R

1
i  R  0.5b   i 2  1 mt  R  0.5b  cos  b yv

R i2  1M t 
 b   i  1
1
2
   b 
 R  0.5b  t v
m b y cos  15
 Determination of Module
b R
Let ,   m , mt  mav
mav  R  0.5b 
 R  0.5b 
mv  mav cos   mt cos 
R
the equation becomes :
i2  1M t  1 From figure,
b     b 
 R  0.5b  mav m yv cos 
2
sin 1 
1
and r1 
mav z
i2  1 2
substituting the value, we get r1
sin 1  and Ro   R  0.5b 
2M t  1
  b 
Ro
b  
mav Z1mav m yv cos 
2
sin 1 
mav z
OR
2  R  0.5b 
2M t 
mav  for   200 1

mav z
 b  Z1 m yv cos 
3

i2  1 2  R  0.5b 

2M t  2

i2  1
mav  1.28 3 mav z 2  R  0.5b 
 b  Z1 m yv
16
Bevel Gear – Force analysis

Figure 2

17
Bevel Gear – Force Analysis

18
 Bevel Gear – Force analysis

Radial Component , Pr  Pt tan  cos 

Thrust Component , Pa  Pr tan  sin 

XX- plane of rotation

YY- plane to the tooth element
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 Bevel Gear – Design Procedure
The following steps may be observed for the design of straight bevel gears.
1. From the given problem, as usual note down the power to be transmitted. gear
ratio, pinion speed, life of drive etc. Then select proper materials and find out
their design stresses and Young's modulus.
2. Calculate the required minimum cone distance, R, based on surface
compressive stress as

Determine ([Mt], E, [σc] as described in spur and helical gears. Select the value of
ψy based on gear ratio using the table (PSG 8.15) (PSG 8.13)

20
 Problems
Qu.1. Design a bevel gear drive to transmit 7 kW at 1600 rpm for the
following data:
Gear ratio = 3
Material for pinion = C45 steel
Life = 10,000 hours
Qu.2. Two straight bevel gears are used in a speed reducer with a
transmission ratio of 2. The wheel is supported on the sides and
the pinion is over hanging. The input is from a 20 kW electric
motor running at 950 rpm. Design the bevel gear.