Creating a Cylindrical Gear with Helical Teeth Стр.

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Suggested Technique for Creating a Cylindrical Gear with Helical Teeth

For a detailed explanation on creating gear teeth with involute profiles refer to the Suggested Technique for Creating an Involute Gear.
It is not trivial to model a cylindrical gear with helical teeth, however, with the implementation of additional design features, such as listed below, this task can be
simplified.

• Variable Section Sweeps: This feature allows the user to create a feature by sweeping a section along the selected trajectories by controlling the
section's orientation, rotation, and geometry along the trajectory.

• Patterning of Copied Features: This allows for simple patterning of the copied feature using the single angular dimension associated with it, and
eliminates tedious design work that would be necessary in order to create a section that will maintain its design intent when rotated about the center axis
of the gear.

Note

The technique described here may not necessarily be the fastest way to create the desired model, and the formulas used within this technique were derived
from a geometrical method and will result in gear geometry slightly less than 100 % accurate. This Suggested Technique is only to describe how to create gear
models with the help of relations and curves derived from relations. In individual applications it is indispensable that functions and relations are used that
correspond with the design intent of the geometry that has to be created, and not with the ones which are used here. It is the responsibility of the technical
designer to utilize the correct formulas for the desired application.
Cylindrical gear with helical teeth
Overview

1. Create the base cylindrical protrusion.

2. Create a datum curve from equation radially positioned with respect to the base protrusion. The definition of this curve includes the bevel angle BETA to
the front surface of the cylinder. If a coordinate system was created on the center axis of the gear, where the z-axis is aligned to the center axis, the curve
can be described by the following formula (cylindrical coordinates). THICKNESS is the face width of the gear and RT is the pitch radius:

========================================
GAMMA = 2 * asin ( (THICKNESS*tan(BETA))/(2.0*RT) )
z = THICKNESS*( t - 0.5)
r= RT
theta = GAMMA*(t -0.5)
========================================
3. Create the tooth profile as a surface using a variable section sweep.
4. Create a solid variable section sweep using Normal to Traj with a section type of Constant using the variable section sweep surface. This feature
finishes the solid geometry of the gear tooth.
5. Create a copy of the tooth rotated about the center axis of the gear by selecting the tooth, Edit > Copy > Edit > Past Special > Apply Move/Rotate

transformations to copies > OK > >, select the center axis, and enter a parameter to define the angle of rotation, and select .
6. Pattern the copied feature at an angle defined by a parameter about the center axis. Note that the original feature cannot be patterned, this would have
entailed a higher degree of design work in terms of flexible placement references and datum planes created on the fly that would allow for the gear tooth
section to be solved correctly no matter what angle the gear tooth was at in a rotational pattern.
So far, only an overview of the steps to create the final gear model have been presented. The final form of the model will only be apparent at the end of
the modeling when all relations have been created and evaluated. The final model will be controlled using the parameters ZA (Number of Teeth), M
(Module), and BETA (Helical angle).

Procedure

1. Create a new part using the mmns_part_solid template.

2. Define the following parameters:

========================================.
THICKNESS (Real Number) = (Face Width) 20
ZA (Integer) = (Number of Teeth) 16
BETA (Real Number) = (Bevel Angle) 20
M (Real Number) = (Module) 4
========================================.
3. Create a cylindrical protrusion with a Symmetric depth of 20 mm (d0) and a diameter of 30 mm (d1) (Figure 1). The dimension symbology will need
to be adjusted accordingly in the relations if a depth of Symmetric is not used.

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Creating a Cylindrical Gear with Helical Teeth Стр. 2 из 7

Figure 1

4. Define the following relations:

========================================
/* RT = > Pitch Radius
RT = ZA*M/2
/*ALPHA => Pressure Angle
ALPHA = 20
/* ev_alpha = > Involute of the Pressure Angle
ev_alpha = tan(ALPHA) - PI*ALPHA/180
/*RG => Base Radius
RG = RT * cos(ALPHA)
/* RF => Dedendum or Minor Radius
RF = RT - M*(1 + 0.25 )
/*RK => Addendum or Major Radius
RK = RT + M
/*Dedendum or Minor Diameter
D1=RF*2
/*Face Width
D0=THICKNESS
/*Radial Tooth position
POS = RG -M*3/2
HT = RK -RG + M*5/4
/*Angle to Rotate the Copied Tooth
COPY=360/ZA
/*Angle Used to Pattern the Copied Tooth
PATTERN=COPY
========================================
5. Create a curve from equation (see Figure 2). This curve will be used later for a variable section sweep trajectory and as a reference for creating the

profile of the tooth. Click > From Equation > Done, select the default coordinate system, Cylindrical, and enter the following equation:

========================================
GAMMA = 2 * asin ( (THICKNESS*tan(BETA))/(2.0*RT) )
z = THICKNESS*( t - 0.5)
r= RT
theta = GAMMA*(t -0.5)
========================================
Save changes to the equations, close the editor, select OK, and regenerate the model.

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Creating a Cylindrical Gear with Helical Teeth Стр. 3 из 7

Figure 2

6. Create a variable section sweep surface with an involute profile. Click to start the sweep, then to create an external sketch which will be
used as the trajectory, select datum plane FRONT, select datum plane RIGHT as a reference and Top as the orientation, and select Sketch. Sketch
the origin trajectory as shown in Figure 3. Use the curve from equation created in Step 5 as a sketcher reference and modify the dimension values,
entering the parameter HT for the height dimension of the sketched line and the parameter POS for the radial position dimension.

Figure 3

Click . Resume feature creation by clicking . Click References and toggle the Section plane control to Normal to Projection. Select

datum plane FRONT, click , and sketch a line symmetric about the center axis as shown in Figure 4 using the upper flat surface as a sketcher
reference.

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Figure 4

This section, a sketched line, will be controlled along the origin trajectory by sketcher relations. Create the sketcher relations shown below to make
sd4, the thickness of the gear profile, dependent on the radius RY. Click Tools > Relations and enter the following (there may be a warning of a
probable error, this may be disregarded):
========================================
RY = RG -M + trajpar* (RK + M/8 - (RG -M))
SG = 2*RG*(PI/(2*ZA) + EV_ALPHA)
if RY < RG
sd4 = RY*SG/RG
ELSE
ALPHA_Y = acos(ZA*M*cos(ALPHA) /(RY *2 ) )
EV_Y= tan( ALPHA_Y ) - PI*ALPHA_Y/180
sd4= 2*RG*(PI/(2*ZA) + EV_ALPHA - EV_Y)
ENDIF
========================================

Complete the surface feature (Figure 5).

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Figure 5

7. Create a solid variable section sweep with the previously created surface as the constant section. Click , click , select datum plane TOP,
and select Sketch. Select the top and bottom flat surfaces of the base protrusion as sketcher references. Sketch a line on datum plane RIGHT,
which should also be in-line with the axis of the cylindrical protrusion, where the start point is aligned to the side of the base protrusion at which the

involute surface was created and end the line at the opposite surface. Click and resume feature creation ( ). Select Options > Constant
Section, while pressing CTRL select the curve from equation created in Step 5. Click References and toggle the Horizontal\Vertical control to

X-Trajectory. Click to enter sketcher. Click , select the boundary of the involute surface using the Loop option (Figure 6), and click

to complete the sketch.

Figure 6

Click to make the feature solid and to complete it. The resulting geometry is displayed in Figure 7.

Figure 7

8. To be able to pattern the tooth around the cylindrical protrusion, you must transform it with the help of the copy functionality. Select the tooth, click

Edit > Copy > Edit > Past Special. Leave Dependent copy checked and click Apply Move/Rotate transformations to copies > OK. Click ,

select the center axis, enter the parameter COPY for the angle, select Yes at the prompt to add a feature relation, and click to complete the
feature.

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Figure 8

9. Select the "Moved Copy" feature from the model tree, right-click > Pattern, select the 22.5 degree dimension and enter the parameter PATTERN.
Select Yes at the prompt to add a feature relation. Enter 5 as a temporary value for the number of instances in the dashboard for the number of

pattern members in the first direction. Click to complete the feature.

10. Add the following relations to drive the number of teeth on the gear where P## is the dimension symbol for the number of pattern instances, and
regenerate the model:

========================================
/* Number of Teeth
P## = ZA - 1
========================================
The gear geometry shown in Figure 9 can now be parametrically controlled using the parameters ZA (Number of Teeth), M (Module), and BETA (Helical
angle).

Figure 9

Download Finished Files for this Technique

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