2.7.

3 Design of helical gear

1. Introduction
(1) Features of helical gear
Contact line leans at an angle with respect to the axis of gear (Left/Right)
There are more teeth engaged simultaneously, a greater contact ratio
Smooth transmission, low noise, high load capacity

(2) Engagement conditions

Normal module mn1=mn2
Normal pressure angle n1= n2
Helical angle b1=-b2

2. Force analysis of helical gear

Ignoring friction forces,
Magnitude of force components

2T1

d1
Fa Ft tan b

Fn

Fr

Ft
Ff
Fn
Fr

Fa

Ff

Ft

tan n
cos b

b
Ft

Ft
Fn
cos b cos n

Smoothness Load capacity

Axial force Complexity
Helical gear b =10~ 25
Double-helical gear b =25~ 40

Directions of force component

Ft, Fr

Identical to the spur gear

Axial force Fa Decided by Direction of helical line and rotational direction.

For driving gear, Fa1 can be decided by Right/left hand rule.
Left hand for left hand helical, Right hand for right hand helical.
If bending direction of fingers matches with the rotational direction,
tip of thumb points to the direction of Fa1.

Fa1

Fr1

Driving
gear
Ft1

For driven gear, direction of Fa2 is opposite to that of Fa1.

Relationship between force components

Fr1 Fr 2

Fn1 Fn2

Fa1 Fa 2

Ft1 Ft2

Example
Side view

Top view

n2

Left hand
helical

n2

Fr2
Fa1 Ft2

Fa2

Fr2
Ft2

Fa2

Ft1

Fa1

Ft1

n1

Fr1

Fr1

Right hand
helical

n1

3. Contact strength of helical gear

Principles:
(1) Considering the strength of an equivalent virtual spur gear

Module =

Normal module of helical gear mn

Pressure angle = Normal pressure angle of helical gear n

Number of teeth = Virtual number of teeth of helical gear zv = z /cos3
Normal force = Normal force of helical gear Fn

d1
d v1
cos 2 b

T1
Tv 1
cos 3 b

b
bv
cos b

zv 2 z 2
uv

u
zv 1 z1

(2) Contact line has an angle with respect to axis, which is advantageous to
reduce contact stress. So we introduce a coefficient of helical angle Z.

 H Z E Z H Z

For spur gear

Coefficient of elasticity
(Table 2-15)

For helical gear

H Z E Z H Z Z

2 KT1 (u 1)
bd12u
2 KT1 (u 1)
bd12u

mn z1
d1
cos b

Coefficient of local
area at pitch point
(Fig. 2-18)

2 cos b b
ZH
cos 2 t tan t

Coefficient of helical angle

Coefficient of
contact ratio

Z cos

Z 0.75 ~ 0.88
The greater number of teeth, the less value of Z.
Under same condition, H_Helical < H_Spur
So, Helical gear has a greater load capacity than spur gear.

For checking contact strength

H Z E Z H Z Z

2 KT1 u 1
min[ HP1 , HP2 ] (MPa)
2
bd1 u

For designing diameter of pitch circle

d1 3 (

Z H Z E Z Z

HP

min[ HP1, HP2 ]

2 KT1 u 1
)
d u
2

(mm)

d b d1
See Table 2-14

For design of geometries

d1 3 (

ZH ZE Z Z

HP

2 KT1 u 1
)
d u
2

(mm)

First computing d1 , then specifying other geometries:

Number of pinion teeth z1 (soft surface, closed gear drive20~40hard

surface, closed gear drive or open gear drive1725)
Initial helical angle , most commonly in range of 10~ 15
Computing mn = d1cos/z1 Rounded up to a basic value and mn 1.5 for
power driving
Computing center distance a =(d1 + d2)/2=mn (z1 + z2) / (2cos) Rounded up to
an integer
Recalculating = cos-1 [mn (z1 + z2) / 2a ]Accurate to second
Recalculating d1, d2 , accurate to the three decimal places

mn z
Attention: d
cos b

Satisfying

d1 d 2
a
2

4. Bending strength of helical gear

(1) Considering the bending strength of equivalent virtual spur gear,
(2) Introducing Yb, coefficient of helical angle.
For helical gear:

2 KT1
F
YFaYSaYY
bd1mn

(MPa)
Coefficient of helical angle

Coefficient of
contact ratio
By virtual number of teeth

zv z / cos
3

See Table 2-20, Table 2-21

Y 0.65 ~ 0.85

Y 0.85 ~ 0.92

For checking the bending strength:

2 KT1
F1
YFa1YSa1YY FP1
bd1mn

(MPa)

2 KT1
F2
YFa2YSa2YY FP2
bd1mn

(MPa)

For designing the normal module:

2 KT1 cos2 YY YFaYSa

mn 3
d z12
FP

(mm)

The greater value

between pinion and gear

Design of Helical Gear

1. Materials and heat treatment

Accuracy
to second

2. Allowable contact stress and bending stress

???
N

Soft surface

Closed

Y
3. Initial valuez1, z2, d, b0
4. Find: K, ZE, ZH, Z, Zb

d1 (
3

Z H Z E Z Z

HP

)2

2 KT1 u 1
d u

b 0 z1
6. Compute mn 0 d1 cos
Rounded up to basic value mn
Easy to
manufacture
and examine

7. Compute a0, Rounded up to a

a0 mn ( z1 z2 ) 2cos b 0

8. Compute helical angel

b arccos[ mn ( z1 z2 ) 2a ]

9. Compute b1, b2, d1,

d2, da1, da2, df1, df2
10. Find Y, Yb, compute Zv1,
Zv2, find YFa, Ysa, Check
bending stress

2KT1
YFaYSaYY FP
bd1m

2.7.4 Design of bevel gear

1. Features of bevel gear drive

Gear drive with vertically intersecting axes

Tooth profile: Straight teeth, helical teeth, curved teeth
Significant vibration and noise, only for low speed transmission, v5 m/s
Teeth on a conical shaped surface
Geometrical factors on large end are standard

Large end

0.5b

Fn

Uneven distribution of load along the tooth width

We only investigate bevel gear of straight teeth,
and axis angle is 90.

For convenience of computing, we assume

Normal force Fn , a concentration force on the pitch cone at the midface of teeth.
Strength of bevel gear Strength of virtual spur gear at the midface of teeth.

2. Geometries of straight bevel gear and its virtual spur gear

1) Geometries of straight bevel gear
Module at the larger end m is standard value,
Dia. of pitch circle

d1 mz 1 ; d 2 mz 2

Ratio of teeth number u z2 / z1 d2 / d1

Cone angle of pitch circle

Cone distance
Coefficient of
tooth width

R 0.5d1 1 u

dm1

tan 1 1 / u; tan 2 u
2

R b/ R

Dia. of pitch circle at the midface of teeth

dm1 (1 0.5 R )d1

Module at the midface of teeth

mm (1 0.5 R )m

2) Geometries of virtual spur gear

Concept of virtual spur gear

Diameter

Number of
teeth
Ratio of
number of
teeth

dv

Midface of
back cone

dv /2

d m1
d v1
cos 1
z1
z v1
cos 1

Virtual spur gear

d v2

dm2

cos 2

zv2

z2

cos 2

z v 2 z2 cos 1
uv

u2
z v1 z1 cos 2

Torque

Tv1 Ft1

d v1
T
1
2 cos 1

Width of teeth = Width of

bevel gear b
Module= Average module mm

3. Force analysis of bevel gear

Considering the normal force as a concentration
force, which acts at the midface of teeth.

Ff

Ignoring the friction force:

Fr

Ft1 tan cos 1

Fa

Ft1 tan sin 1

Ff
Fn
Ft

2T1 d m1

Fn Ft1 cos
Ft, Fr , identical to the spur gear

Ft1 Ft2

Fr1 Fa2

Fa pointing towards the large end

Fa1 Fr2

Example problem
1
n1

Ft1 Fr1
Fr2

Fa1

Ft2
Fa2

Ft2 = Ft1

n2

Fr2= Fa1 Fa2= Fr1

4. Contact fatigue strength of bevel gear

Considering the equivalent virtual spur gear at the midface of teeth.

Ignoring the influence of contact ratio.
Force checking

H ZH ZE

4 KT1
HP
2 3
0.85 R (1 0.5 R ) d1 u

Effective face width

beH0.85b

For design

d1 3 (

ZHZE

HP

4 KT1
)
0.85 R (1 0.5 R )2 u
2

For design

Discussions

ZE ZH
4 KT1

d1
2

0
.
85

(
1

0
.
5

)
u
R
R
HP
3

mm

Dia. of pitch circle at the large

end of pinion

ZE, ZH, HP, identical to the process of spur gear

Often b1 b2, easier to assemble and coincide the vertex
Often u 5, limiting the diameter of bigger bevel gear, easier to manufacture
After specifying d1 , other geometries needs to be decided
Computing m=d1/z1,
rounded up to standard value
Calculating d1= mz1, z2, d2, u , et al
R 0.5d
Initial z1

1 u2

Dont round up R !

5. Bending fatigue strength of bevel gear

In the like manner, considering the bending fatigue strength of virtual gear.

Ignoring the influence of contact ratio, using the geometries of virtual gear,
depending on

2KT1
F
Y Y Y
3 2 Fa Sa
d m z1

Spur gear:
For checking

4 KT1

R (1 0.5 R ) m z
2

1 u

YFaYSa FP
zv z / cos

Virtual number of teeth

For design

3 2
1

4 KT1

YFaYSa

R (1 0.5 R )2 z12 1 u 2 FP
Bigger value

Example:

A double gear reducer is driven by an electrical motor.

Inputting power P17kW.
Inputting rotational speed n11000r/min.
Speed ratio of the first stage i 4.6
Unidirectional, slight impact.
Life expectancy 10 years, 8h per day.
Try to design the first gear drive.

1. Requirements
Medium speed and medium load.
Either soft surface or hard surface is OK.

Second gear drive

Using helical gear for smooth movement.

2. Design plan
Plan A: Helical gear
45 steel, soft surface
Plan B: Helical gear
45 steel, hard surface
First gear drive

3. Design process
Design contents

Design principles

Plan A

Plan B

1Material and heat treatment

Pinion
Gear

Table 2-11

H.T. of pinion
H.T. of gear

HB of pinion > HB of gear

HB of pinion
Table 2-11, middle value
HB of gear
2Allowable contact stress and bending stress
Fig. 2-24
Contact H lim1
stress
Bending
stress

H lim 2
F lim1
F lim 2

Fig. 2-26
Fig. 2-30
Fig. 2-28

45
45
H&T
Norm.
230HBS
190HBS

45
45
Case hardening
Case hardening

50HRC
50HRC

580
550
220

1170
1170
340

210

340

Design content
load cycle

Coefficient of
contact life
Coefficient of
bending life
Min. safety
coefficient

N 1 N1 60an1t 60 1 1000 (10 300 8)

N 2 N 2 N 1 / i 300 day per year
Z N1
Pitting not
ZN2
YN1
YN1

Fig. 2-27

Fig. 2-32

allowable
Line 1

Plan A

Plan B

14.4108
3.13108
1
1
1
1

S H min

Table 2-14

SF min

Table 2-14
HP 1 H lim1 Z N1 / SH min

1.4
580

1170

HP 2 H lim 2 Z N 2 / SH min

550

1170

314

486

300

486

HP 1
Allowable
contact stress

HP 2

Allowable
bending stress

Design principles

FP 1 FP 1 F lim1YSTYN1 / SF min YST 2

FP 2 FP 1 F lim1YSTYN1 / SF min

Design content

Design principles

Plan A

Plan B

3Specifying initial parameters

Initial helical angle

No. of teeth

z1

z2

Modification
Load coefficient
Where

12

Table 2-1 Assuming the linear

speed v9m/s

Precision grade
Coe. of face width

In the range of 10~15

K
KA
Kv
K
K

Grade 8
0.9

0.5

26

21

Table 2-7, slight impact

119
0
1.898
1.25

97
0
2.234
1.25

Fig. 2-6, Kv1.02~1.2

1.1

1.1

Table 2-9, soft1~1.2hard1.1~1.35

1.15

1.25

Table 2-8 K1.2~1.4

1.2

1.3

Table 2-14
Closed, soft z120~40
Closed, hard z117~25
z2z1i z14.6

K K A K v K K

Design content

Design principles

Plan A

Plan B

4Design and calculation

Principles

Closed, soft: Design by contact

strength, Checking by bending stress
Closed, hard: Design by bending
strength, Checking by contact strength

Plan A

d1

ZE Z H Z Z

HP

Z E Table 2-15 MPa

Coe. of local area
Z H Fig. 2-18
Coe. of contact ratio Z Z0.75~0.88
Coe. of helical angle Z Z cos b cos 12

HP HP2<HP1 so, HP=HP2

Ratio of teeth number u Speed reducing, u i

Closed,
hard

2 KT1 u 1

u
d

Coe. of elasticity

Allowable contact stress

Closed,
soft

mm

189.8
2.45
0.8
0.989
550MPa
4.6

Design content
Torque

T1

Design principles

T1 9550 103

P1
17
9550 103
n1
1000

Plan A
162350N.mm

Dia. of Pitch circle

2

189.8 2.45 0.8 0.989 2 1.898 162350 4.6 1 71.986mm

d1 3

550
0.9
4.6

Normal module

mn

d1 cos b 71.986 cos 12

mn

z1
26
mn ( z1 z2 ) 3( 26 119)

2 cos b
2 cos 12

Cent distance

Accurate helical
angle

b cos 1

mn ( z1 z2 )
3( 26 119)
cos 1
2a
2 222

2.71mm
Rounded up to 3

222.36mm
Rounded up to
222

11o33'21''

Design content
Accurate dia. of
pitch circles

d1
d2

Design principles

Plan A

mn z1 / cos b 3 26 / cos 11o 33' 21"

3 119 / cos 11o 33'21"

79.61mm
364.39mm

Satisfyingd1d2/2a
Face width

Line speed

Coe. of tooth
profile

b1 b2 (5 ~ 10)mm

d1n1
60 1000

Rounded up

79.61 1000
60000

b272mm
b178mm
4.17m/s
OK!

2 KT1
F
YFaYSaYY FP
bmn d1

Checking bending
strength
Virtual teeth
number

b2 d d1 0.9 79.61 71.65

z v1
zv2
YFa 1
YFa 2

zv

z
cos 3 b

Fig. 2-20

27.65
126.54
2.6
2.2

Design contents
Coe. of stress
modification
Coe. of contact ratio

Coe. of helical angle

YSa1
YSa2
Y
Y

Design principles
Fig. 2-21

Y 0.65 ~ 0.85
Y 0.85 ~ 0.92 Bigger , bigger Y

Plan A
1.61
1.82
0.75

0.89

F1 2 1.898 162350 2.6 1.61 0.75 0.89 Bending

Checking bending
stress

72 3 79.61
100 MPa HP 1 314 MPa

strength OK!

YFa2YSa2
2.2 1.82
100
YFa1YSa1
2.6 1.61
96 MPa HP 2 300 MPa

Bending
strength OK!

F2 F1

The endclosed, soft face

Design contents
Design by
bending
strength

Virtual number
of teeth
Coe. of tooth
form
Coe. of stress
modification

Design principles

mn 3

Plan B

2 KT1 cos 2 b YY YFaYSa

z1 d
2

FP

mm Closed, hard
surface

z v1

z v1 z1 / cos 3 b 21 / cos 3 12o

22.44

z v2

z v2 z2 / cos 3 b 97 / cos 3 12o

103.65

Fig. 2-20

2.76
2.22

Fig. 2-21

1.55
1.79

YFa 1
YFa 2
YSa1
YSa2

Coe. of contact
ratio

Y 0.65 ~ 0.85

Coe. of helical
angle

Y 0.85 ~ 0.92

The more teeth,

the less value

0.8

0.89

Design contents
P
Comparing
bending strength

Design principles

YFa1YSa1

2.76 1.55

0.0088
486

YFa2YSa2

FP1

Plan B

FP2

mn 3
Normal modulus

Considering
pinion

2.22 1.79
0.0082
486

2 KT1 cos 2 b YY YFaYSa

z1 d
2

FP

2
o
2

2
.
234

162350
cos
12
0.8 0.89
3
0.0088
2
21 0.5
2.70 mm Rounded up, mn2.75mm

Center distance

mn ( z1 z2 ) 2.75 ( 21 97)

2 cos b
2 cos 12

165.87mm
Rounded to 166

Design contents

Design principles

Plan B

mn ( z1 z2 )
2.75(21 97)
cos 1
2a
2 166

Accurate helical
angle

b cos 1

Accurate pitch
diameter

d1
d2

Face width

mn z1 / cos b 2.75 21 / cos 12o12' 6" 59.08mm

272.92mm
2.75 97 / cos 12o12'6"
b2 d d1 0.5 59.08 29.54
b230mm

Linear speed
Checking
contact stress
Coe. of elasticity
Coe. of local area

12o12'6''

b1 b2 (5 ~ 10)mm

59.08 1000
v

60 1000
60000

b135mm

d1n1

H ZE Z H Z Z
Z E Table 2-15
Z H Fig. 2-18

MPa

3.09m/s
OK!

2 KT1 u 1
HP
2
u
bd1

MPa

189.8
2.45

Design contents
Coe. of contact ratio
Coe. of helical angle

Z Helical gear Z0.75~0.88

Z Z cos b cos 1212' 6"

Allowable contact stress

Ratio of teeth

Design principles

HP

Plan B
0.82
0.989

HP2HP1 1170MPa

1170MPa

Speed reducer u i

4.6

H Z Z Z Z 2 KT1 u 1
E H
2
u
bd
1
Checking contact
stress
2 2.234 162350 5.6
189.8 2.45 0.82 0.989

2
30 59.08
4.6

1089 MPa HP 1170 MPa

Conclusion: contact strength is OK!

The end( closed, hard surface)

Comparison of two design plan

Design contents

Plan A

Plan B

Helical angle

45
P: H&T
G:Norm.
11o33'21''

No. of teeth

z1
z2

26
119

21
97

Modulusmm

mn

2.75

Pitch diameter
mm

d1
d2

79.61
364.39

59.08
272.92

78
72
222

35
30
166

Material
Heat treatment

b1
Face width
b2
mm
a
Center distancemm

45
Case
Hard.
12o12'6''

Analysis:
Plan A: soft surface, easy
to manufacture, low cost.
But structure size larger.

Plan B: hard surface,

complicated to
manufacture, high cost.
But smaller structure size,
light weight, high
strength.
Plan A for common use
Plan B: for great load
and compact size

2.8 Other Considerations of Gear Drive Design

1. Efficiency of gear drive

Power loss of gear drive
Friction loss
Oil resistance loss
Bearing friction loss
Efficiency of closed gear drive

= 1 2 3

Most
significant

1 Efficiency in mesh, decided by precision grade;

2 Churning loss;
3 Bearing efficiency.
Average efficiency of closed cylinder gear drive, 0.96-0.99;
Average efficiency of closed bevel gear drive, 0.94-0.98;

2. Lubrication of gear drive

Teeth in mesh

Relative sliding

Functions of lubrication:
Cooling
Anti-corrosion
Vibration absorbing
Noise reduction

Friction and wearing

v 12 15m/s

Churning
Types of
lubrication

Oil sump

Injection
v 15m/s

3. Structure design
By strength design:
To specify geometrical parameters
Such as center distance,
module, helical angle
By structure design
To specify pattern and size of spoke and hub
(decided by dia. of addendum circle)
(1) Gear shaft

The distance from dedendum to root of gear e

Cylinder geare<2.5mn
Bevel geare<1.6m

(2) Solid gear

Dia. of addendum circle da200mm

Forged
gear blank

(3) Web
Dia. of addendum circle da200~500mm

Forged
gear blank

4. Spoke
cast iron or cast steel
Dia. of addendum circle da500mm

Homework-9
Specify the helical direction of Gear 1 and Gear 2.
Mark the directions of each force components.

Tips: Both Gear 2 and Gear 3 exert axial forces on Shaft II. We can
offset them after we specify the helical direction.