Jan Klingelnberg

Editor

Bevel Gear
Fundamentals and Applications
Bevel Gear
ThiS is a FM Blank Page
Jan Klingelnberg
Editor

Bevel Gear
Fundamentals and Applications
Editor
Jan Klingelnberg
Klingelnberg GmbH
Peterstraße 45, 42499
Hückeswagen
Germany

Editorial team:
Hartmuth Müller
Klingelnberg GmbH, Peterstraße 45, 42499 Hückeswagen, Germany

Joachim Thomas
ZG Hypoid GmbH, Georg-Kollmannsberger-Straße 3, D-85386 Eching-Dietersheim,
Germany

Hans-Jürgen Trapp
Klingelnberg GmbH, Peterstraße 45, 42499 Hückeswagen, Germany

Claude Gosselin Ing. Ph.D., Involute Simulation Softwares Inc., Quebec, Canada

ISBN 978-3-662-43892-3 ISBN 978-3-662-43893-0 (eBook)

DOI 10.1007/978-3-662-43893-0

Library of Congress Control Number: 2015949639

© Springer-Verlag Berlin Heidelberg 2016

This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part of
the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations,
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Printed on acid-free paper

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The registered company is Springer-Verlag GmbH Berlin Heidelberg
Preface

In all textbooks on gear technology, cylindrical gears usually come to attention first
because of their wide use, whereas bevel gears are dealt with superficially. There-
fore, readers with a deep interest in bevel gears are not satisfied.
Although the essential differences between bevel and cylindrical gears are
always outlined, the true characteristics and features of bevel gears, and their
“three-dimensional” nature which varies along the face width, are not sufficiently
detailed.
In this book, a team of authors from academia and industry aims to provide a
comprehensive textbook on bevel gears.
After covering the major fields of application for these machine elements, this
book presents the geometrical attributes of bevel gears and the different cutting
methods based on gear theory.
The three-dimensional aspect of the gear teeth is treated in detail, with chapters
on tooth flank development, load capacity, and noise behaviour. Descriptions of
production processes and necessary technologies provide a knowledge base for
sound decision-making.
The aim of this textbook is to introduce the reader to all aspects of the complex
world of bevel gears and to present in detail and in understandable form the results
of rapid developments in recent years
I like to thank all the co-authors for their contributions and for sharing their
knowledge gained through many years of professional experience.

Hückeswagen, Germany Jan Klingelnberg

2016

v
ThiS is a FM Blank Page
Symbols and Units

Symbols Definition Units

A Auxiliary factor for dynamic factor –
AE Distance between contact points A and E (complete path of mm
contact)
Am Area of the half of ellipse of contact pressure distribution over mm2
the middle contact line
Ar Area of the half of ellipse of contact pressure distribution over mm2
the root contact line
At Area of the half of ellipse of contact pressure distribution over mm2
the tip contact line
a Hypoid offset mm
ap Hypoid offset in the pitch plane mm
arel Relative offset –
av Centre distance of virtual cylindrical gears mm
B Accuracy grade acc. ISO 17485 –
B Auxiliary factor for dynamic factor –
BM Thermal contact coefficient N
mm =2 m =2 s =2 K
1 1 1

b Minor half-axis of the contact ellipse mm

b Face width mm
b2eff Effective face width (wheel) mm
be Face width from calculation point to outside mm
bH Semi-width of Hertzian contact band mm
bi Face width from calculation point to inside mm
bv Face width of virtual cylindrical gears mm
bveff Effective face width of virtual cylindrical gears mm
Ca Tip relief μm
Ceff Effective tip relief μm

vii
viii Symbols and Units

Symbols Definition Units

CZL,CZR,CZV, Factors for determining lubricant film factors –
C1,2, C2H Experimental weighting factors for calculation of bulk –
temperature
c Component of circumferential speed in plane of contact m/s
c Clearance mm
cbe2 Face width factor –
cham Mean addendum factor of wheel –
cM Specific heat per unit N m/kg K
cα Component of circumferential speed in plane of contact in tooth m/s
depth direction
cβ Component of circumferential speed in plane of contact in m/s
direction of face width
cγ Mesh stiffness N/(mm ∙μm)
D Sum of damage –
D1, D2, D3 Integration constants of the sliding velocity over the path of –
contact
da Tip diameter of virtual crossed axes helical gear mm
dae Outside diameter mm
db Base diameter of virtual crossed axes helical gear mm
de Outer pitch diameter mm
dm Mean pitch diameter mm
ds Pitch diameter of virtual crossed axes helical gear mm
dT Tolerance diameter mm
dv Reference diameter of virtual cylindrical gear mm
dva Tip diameter of virtual cylindrical gear mm
dvan Tip diameter of virtual cylindrical gear in normal section mm
dvb Base diameter of virtual cylindrical gear mm
dvbn Base diameter of virtual cylindrical gear in normal section mm
dvn Reference diameter of virtual cylindrical gear in normal section mm
d*v Pitch diameter of virtual cylindrical gear acc. FVA411 mm
E Modulus of elasticity (Young’s modulus) N/mm2
E Auxiliary factor for tooth form factor –
efn Tooth slot width at the bottom of the tooth space mm
F1, F2 Auxiliary factors for mid-zone factor –
Fax Axial force N
Fmt Tangential force at mean diameter N
Fmtv Tangential force of virtual cylindrical gears N
Fn Normal force N
Fp Cumulative pitch deviation, total μm
FpT Cumulative pitch tolerance, total μm
FR Friction force N
Fr Runout deviation μm
Frad Radial force N
FrT Runout tolerance μm
Symbols and Units ix

Symbols Definition Units

Ft Tangential force N
Fx Index deviation μm
F’i Single-flank composite deviation, total μrad/μm
F”i Double-flank composite deviation, total μm
F”r Double-flank runout deviation μm
f Distance from mid-point M to any line of contact mm
fm Distance from mid-point M to the mean line of contact mm
fmax Maximum distance to the middle line of contact mm
fpt Single pitch deviation μm
fptT Single pitch tolerance μm
fαlim Influence factor of limit pressure angle –
fr Distance from mid-point M to the root line of contact mm
ft Distance from mid-point M to the tip line of contact mm
f’i Tooth-to-tooth single-flank composite deviation μrad/μm
f’k Short-wave part of single-flank deviation μrad/μm
f’l Long-wave part of single-flank deviation μrad/μm
f”i Tooth-to-tooth double-flank composite deviation μm
f”e Eccentricity of double-flank composite deviation μm
G Movement of axis in case of sliding mm
G Auxiliary factor for tooth form factor N
G Auxiliary value for integration of sliding velocity over path of –
contact
gan Length of the addendum part of the path of contact in the mm
normal section
gfn Length of the dedendum part of the path of contact in the mm
normal section
gn Distance of a contact point to the pitch or helix point on the mm
contact line in the normal plane
gt Distance of a contact point to the pitch or helix point on the mm
contact line in the pitch plane
gvα Length of the path of contact of virtual cylindrical gears mm
gvαn Length of the path of contact of virtual cylindrical gears in the mm
normal section
H Auxiliary factor for tooth form factor –
HB Brinell hardness –
HRC Rockwell hardness –
HV Vickers hardness –
HV Tooth mesh loss factor –
hae Outer addendum mm
ham Mean addendum mm
hamc Mean chordal addendum mm
ha0 Tool addendum mm
hfe Outer dedendum mm
hfi Inner dedendum mm
x Symbols and Units

Symbols Definition Units

hfm Mean dedendum mm
hFa Arm of the bending moment for tooth root stress mm
(load application at tooth tip)
hm Mean whole depth mm
hmw Mean working depth mm
ht1 Pinion whole depth perpendicular to root cone mm
h1, h2 Auxiliary variables to determine the sliding velocity –
I Integral of sliding velocity distribution –
jen Outer normal backlash mm
jet Outer transverse backlash mm
jmn Mean normal backlash mm
jmt Mean transverse backlash mm
KA Application factor –
KBα Transverse load factor for scuffing –
KBβ Face load factor for scuffing –
KF0 Lengthwise curvature factor for bending stress –
KFα Transverse load factor for bending stress –
KFβ Face load factor for bending stress –
Kgm Sliding factor for calculation of the friction coefficient –
KHα Transverse load factor for contact stress –
KHβ Face load factor for contact stress –
Kmp Number of mates meshing with the actual gear –
Kv Dynamic factor –
kc Clearance factor –
kd Depth factor –
khap Basic crown gear addendum factor (related to mmn) –
khfp Basic crown gear dedendum factor (related to mmn) –
kt Circular thickness factor –
k1, k2 Auxiliary constants for the calculation of tooth mesh loss factor –
L Auxiliary factor for the calculation of the dimensions of the –
contact ellipse
La Auxiliary factor for correction factor –
lb Length of contact line mm
lbm Theoretical length of middle line of contact mm
l’bm Projected length of middle line of contact in consideration of mm
inclined lines of contact
met Outer transverse module mm
mmn Mean normal module mm
mmt Mean transverse module mm
msn Normal module of the virtual crossed axes helical gear mm
NL, NI Number of load cycles –
n Rotational speed 1/min
nI Number of load cycles of class I –
np Number of mates meshing with the actual gear –
Symbols and Units xi

Symbols Definition Units

P Nominal power W
pe Base pitch mm
pen Normal base pitch mm
pet Transverse base pitch mm
p* Related peak load –
qs Notch parameter –
R Movement of axis in case of rolling mm
Ra ¼ CLA ¼ AA arithmetic average roughness μm
Re Outer cone distance mm
Ri Inner cone distance mm
Rm Mean cone distance mm
Rz Mean roughness μm
R Distance of a point on a contact line to the helix axis mm
rc0 Tool radius mm
rs Half diameter of crossed axes helical gear mm
SA Distance of contact points S and A at the contact line of the mm
virtual crossed axes helical gear
SB Safety factor for scuffing (contact temperature method) –
SE Distance between contact points S and E at the contact line of mm
the virtual crossed axes helical gear
SF Safety factor for bending stress (against breakage) –
SF min Minimum safety factor for bending stress –
SFZG Load stage in FZG- A/8,3/90-test –
SH Safety factor for contact stress (against pitting) –
SH min Minimum safety factor for contact stress –
Sint S Safety factor for scuffing acc. integral temperature method –
SS min Minimum required safety factor for scuffing –
sFn Tooth root chord in calculation section mm
smn Mean normal circular tooth thickness mm
smnc Mean normal chordal tooth thickness mm
spr Amount of protuberance mm
T Torque Nm
T1T Torque of load stage of the scuffing test Nm
tB Mounting distance mm
txi Front crown to crossing point mm
txo Crown to crossing point (hypoid) mm
tz Pitch apex beyond crossing point mm
tzF Face apex beyond crossing point mm
tzi Crossing point to inside point along axis mm
tzm Crossing point to mean point along axis mm
tzR Root apex beyond crossing point mm
U Voltage V
u Gear ratio –
ua Equivalent gear ratio –
xii Symbols and Units

Symbols Definition Units

VL Lubricant factor for calculation of the friction coefficient –
VR Roughness factor for calculation of the friction coefficient –
VS Slip factor for calculation of the friction coefficient –
VZ Viscosity factor –

vBel Angle between sum of velocities and the pitch cone
vF Tangential velocity at the tooth flank m/s
vg Sliding velocity m/s
vg,par Sliding velocity parallel to the contact line m/s
vgα Sliding velocity in profile direction m/s
vgβ Sliding velocity in lengthwise direction m/s
vgγ Total sliding velocity m/s
vmt Tangential speed on the reference cone at mid-face width m/s
vt Tangential speed at any contact point m/s
vΣ,C Sum of velocities at pitch point C m/s
vΣ,h Sum of velocities in the profile direction m/s
vΣ,m Mean sum of velocities m/s
vΣ,s Sum of velocities in the lengthwise direction m/s
vΣ,senk Sliding velocity vertical to the contact line m/s
vΣα Sum of velocities in the profile direction m/s
vΣβ Sum of velocities in the lengthwise direction m/s
vΣγ Total sum of velocities m/s
Wm2 Mean normal slot width of wheel mm
w Component of tangential speed in the tangential plane m/s

wBel Angle between contact line and the pitch cone
wBn Normal unit load N/mm
wBt Transverse unit load N/mm
wBt eff Effective transverse unit load N/mm
wBt max Maximum transverse unit load N/mm
wα Tangential speed component in the tangential plane in the m/s
profile direction
wβ Tangential speed component in the tangential plane in the m/s
lengthwise direction
XBE Geometry factor (integral temperature method) –
XCa Tip relief factor –
XE Running-in factor –
XG Geometry factor (contact temperature method) –
XJ Mesh approach factor (contact temperature method) –
XL Lubricant factor –
XM Thermal flash factor N
mm =2 m =2 s =2 K
1 1 1

Xmp Multiple mating factor –

XQ Mesh approach factor (integral temperature method) –
XR Roughness factor –
XS Lubricant system factor –
Symbols and Units xiii

Symbols Definition Units

XW Structural (welding) factor –
XWrelT Relative welding factor –
XΓ Load sharing factor (scuffing) –
Xαβ Influence factor for pressure and spiral angle –
Xε Contact ratio factor (scuffing) –
xhm Profile shift coefficient –
xsm Thickness modification coefficient (backlash included) –
xsmn Thickness modification coefficient (theoretical) –
YFa Tooth form factor for load application at tip –
YK Bevel gear factor –
YLS Load sharing factor (bending strength) –
YNT Life factor of the standard test gear –
YR rel T Relative surface factor –
YSa Stress correction factor for load application at tooth tip –
YST Stress correction factor for the dimensions of standard test gear –
YX Size factor for tooth root stress –
Yε Contact ratio factor (tooth root) –
Yσ rel T Relative sensitivity factor –
ZE Elasticity factor –
ZF Material factor for the calculation of the semi-width of the (N/mm2)1/3
Hertzian contact band
ZH Zone factor –
ZHyp Hypoid factor –
ZK Bevel gear factor (pitting stress) –
ZL Lubricant factor –
ZLS Load sharing factor (pitting) –
ZM-B Mid-zone factor –
ZNT Life factor of the standard test gear –
ZR Roughness factor for contact stress –
ZS Slip factor –
Zv Speed factor –
ZW Work hardening factor –
ZX Size factor (pitting) –
Zβ Helix angle factor for pitting stress –
z0 Number of blade groups –
z Number of teeth –
zp Number of crown gear teeth –
zv Number of teeth of the virtual cylindrical gear –
zvn Number of teeth of the virtual cylindrical gear in the normal –
section

αan Normal pressure angle at tooth tip

αdC Nominal design pressure angle on coast side

αdD Nominal design pressure angle on drive side
xiv Symbols and Units

Symbols Definition Units


αe Effective normal pressure angle acc. [ISO23509]

αeC Effective pressure angle on coast side

αeD Effective pressure angle on drive side

αet Effective pressure angle in the transverse section acc.
[ISO23509]

αFan Load application angle at tip circle of the virtual spur gear

αFanΔ Auxiliary angle for determination of the bending arm at tip

αlim Limit pressure angle

αn Normal pressure angle

αnD Generated normal pressure angle on drive side

αnC Generated normal pressure angle on coast side

αsn Normal pressure angle of the virtual crossed axes helical gear

αst Transverse pressure angle of the virtual crossed axes helical
gear

αt Pressure angle in the transverse section

αvt Transverse pressure angle of the virtual cylindrical gear

αwn Normal working pressure angle

αwt Transverse working pressure angle

βb Spiral angle at the base circle

βB Inclination angle of the contact line

βe Outer spiral angle

βi Inner spiral angle

βm, βv Mean spiral angle

βs Helix angle of the virtual crossed axes helical gear

βvb Helix angle at base circle of the virtual cylindrical gear

βw Working helix angle
Γ Parameter on the line of action –

γ Angle of the tangential velocity relative to the contact line

γ Auxiliary angle for the length of the line of contact

γα Auxiliary angle for tooth form and tooth correction factors
Δa Centre distance variation μrad
Δa” Double-flank centre distance variation μrad
Δbx1 Pinion face width increment mm
Δgxi Increment along pinion axis from calculation point to inside mm
Δgxe Increment along pinion axis from calculation point to outside mm
ΔH Pinion mounting distance variation mm
ΔJ Wheel mounting distance variation mm
ΔV Hypoid offset variation mm
Δφ Rotation angle variation μrad

δa Face angle

δf Root angle

δ Pitch angle
εa Recess contact ratio –
εf Approach contact ratio –