Chapter - 3

Design of bevel gear

3.1 Introduction
The bevel gears are used for transmitting power at a constant velocity ratio
between two shafts whose axes intersect at a certain angle. The pitch cones of
bevel gears are analogous to the pitch cylinders of spur and helical gears. The
basic shape of a bevel gear tooth is almost the same as that of the spur gear. The
tooth tapers off as it approaches the apex. The contour of the tooth also varies
along its entire length. The angle between the shafts will depend on the
conditions of drive. It is usually 9o, but can have other angles also.
Classification of Bevel Gears
The bevel gears may be classified into the following types, depending upon the
angles between the shafts and the pitch surfaces.
Mitre gears. When equal bevel gears (having equal teeth and equal pitch
angles) connect two shafts whose axes intersect at right angle, then they
are known as mitre gears.
Angular bevel gears. When the bevel gears connect two shafts whose axes
intersect at an angle other than a right angle, then they are known as
angular bevel gears.
Crown bevel gears. When the bevel gears connect two shafts whose axes
intersect at an angle greater than a right angle and one of the bevel gears
has a pitch angle of 90º, then it is known as a crown gear.
Internal bevel gears. When the teeth on the bevel gear are cut on the
inside of the pitch cone, then they are known as internal bevel gears.

3.2 Nomenclature of bevel Gear

1. Pitch cone. It is a cone containing the pitch elements of the teeth.
2. Cone centre. It is the apex of the pitch cone. It may be defined as that point
where the axes of two mating gears intersect each other.
3. Pitch angle. It is the angle made by the pitch line with the axis of the shaft.
It is denoted by ‘θP’ or δ

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 7. Face angle. It is the angle subtended by the face of the tooth at the cone
centre. It is denoted by ‘φ’. The face angle is equal to the pitch angle plus
3.4 Geometry of the bevel gear
addendum angle.
Let,
8. Root angle. It is the angle subtended by the root of the tooth at the cone
θp1 = pitch
centre. angle by
It is denoted for‘θR’.
the pinion,
It is equalθsto =theAngle b/n the
pitch angle twodedendum
minus shaft axis angle.
θp2
9. Back= pitch angle for
(or normal) cone.theIt gear Dp = pitch
is an imaginary cone, diameter of the
perpendicular pinion
to the pitch
S.noDp
cone at the Description
end of the tooth.
= pitch diameter of the gear For Pinion For Gear
10. Back cone distance. It is the length of the back cone. It is denoted by ‘RB’.
tan
1 θp1 = of, teeth
It Number
is also called
θp1 = tan -1 () = tan -1(18/51)
back cone radius. Z1 = 18 = 19.40 Z2 = 51

 
tan
11.  θp2 = , Itθp2
Backing. tan -1of()the
is the=distance =  pitch
tan -1(51/18)
point (P) from =the
70.60
back of the
  boss,
θs = 900to the pitch point of the gear. It is denoted by ‘B’.
parallel
212.determine
To Crown
Pitch height.
Circlethe It is the
module,
Diameter wedistance
can usedofthe
1 =the crown
following
m1*Z 1 point (C) from the cone
formula;- d2 = centre
m1*Z2
(O), parallel
M = to the axis of the gear. It is denoted by ‘HC’.
    Mounting
13.Where , height. It is the distance d1 =of2.5*18 = 45mm
the back of the boss from thed2 cone
= 2.5*51 = 127.5mm
centre.
T1 It is torque
= Pinion denoted by ‘HM’. Z1 = Number of teeth of the pinion
3 Transmission Ratio i = n1/n2 = Z2/Z1 = 52/18 = 2.833
14. Pitch diameter. It is the diameter of the largest pitch circle.
= pitch
415.Pitch
angle
Outside
Cone
of
oranglethe pinion
addendum cone diameter. δbp = The
θp1= tanIt(isZ1the
-1
allowable stress
/Z2)maximum diameter θp2of the-1( Z2/Z1)
= tan
δbpof=the,gear. Itδeis =equal
teeth the endurance limitsofofthe
to the diameter theblank
material
from which
  the( gear
From the can
Shaft be cut.
angle
selected Mathematically,
ismaterial
equal toδe
90 =0
outside
θp
) 370Mpa 1= tan diameter,
-1
and( 18/51)
δbp = 180N/mm2 θp2= tan ( 51/18)
-1

T1 = DO = DP + 2 a cos θP
    52.52 from the previous calculation
θp1= 19.40 θp2= 70.6.90
Z1 = 18, where DP = Pitch
δ1 = 19.40circle diameter,
5 Shaft angle (£) a = Addendum, and θs = θp1 + θp2
M= = 2.17 implies m= angle.
θP = Pitch 2.5
    θs = 17.10 + 72.90 = 900
16. Inside or dedendum cone diameter. The inside or the dedendum cone
diameter
6 Tip Circle is given by
Diameter da1 = d1 + 2*m cos θp1 da2 = d2M= 2.5cos θp2
+ 2*m
Dd = DP – 2d cos θP
    d = 45 + 2*2.5 cos 19.40 da2 = 127.5 + 2*2.5cos70.60
Where Dd = Inside a1diameter, and
    d = Dedendum.
da1 = 49.7mm da2 = 129.16mm
3.3 Material Selection for the spur gear`
7 Cone Distance R = d1/ 2*sin θp1 R = d2/ 2*sin θp2

    R = 45/ 2*sin 19.4 R = 260/ 2*sin70.6

    R = 68mm R = 68mm

8 Face Width bmax < R/3

    b = R/3 = 68/3 = 23 mm

9 Middle Circle Diameter dm1 = d1 - b sin θp1 dm2 = d2 - b sin θp2

    dm1 = 45 - 23 sin 19.4 dm2 = 127.5- 23sin 70.6

    dm1 = 37.36m dm2 = 105.8mm

    dm1≈ 38mm dm2 ≈ 106mm

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s.no Description For Pinion For Gear

10 Virtual number of teeth ( ZV1) ZV1 = Z1 / COS θp1 ZV2 = Z2 / COS ð2

    ZV1 = 18 / COS 19.4 ZV2 = 51 / COS 70.6

    ZV1 = 21.2 ZV2 = 83.78

11 Middle Module mm = dm1/Z1 = dm2/Z2

    mm = 37.36/18 = 105.8/51 = 2.07

12 Top Clearance ( C ) C = 0.2 * M = 0.2 * 2.5= 0.5mm

13 Whole Depth ( h ) h = 2.2 * M = 2.2 * 2.5 = 5.5 mm

14 Addendum ha1 = ha2 = m = 2.5mm

15 Dedendum hf1 = hf2 = 1.2 * m

    hf1 = hf2 = 1.2 * 2.5 = 3 mm

16 Addendum angle øa1= øa2 == tan -1( M/R)

    øa1= øa2 == tan -1( 2.5/68)

    øa1= øa2 == 2.10

17 Dedendum angle øf1= øf2 == tan -1( 1.2M/R)

    øf1= øf2 == tan -1( 1.2*2.5/68)

    øf1= øf2 == 2.530

18 Blank Cone angle (Face angle) da1 = θp1+ øa1 da2 = θp2+ øa2
    da1 = 19.4 + 2.1 = 21.50 da2 = 70.6+ 2.53 = 73.130

19 Crown height (CH1) CH1 = d2/2 - msinθp1 CH2 = d1/2 - msinθp2

    CH1 = 127.5/2 – 2.5*sin 19.4 CH2 = 45/2 – 2.5*sin70.6

    CH1= 62.9mm CH2 = 20.14mm

 20  Back cone distance  Ra1 = Rtanθp1  Ra2 = Rtan θp2

= 68*tan19.4 = 23.95 = 68tan70.6 = 190.97

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Ft= 2811.56N

Fr1 = 965.22N

Fr2 = 339.9N

Fa1 = 339.9N
Fa2 = 965.22N

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Circumferential force at the middle is give by
Ftm =
For calculating the bending and other stress consider the force is taken to
act at the tip corner of the gear tooth

qk1 qe1
qk2 qe2
From, the chart qk1 =3 qe1 = 1
qk2 = 2.4 qe2 = 1
The allowable bending stress can be taken from the table which is

There for Ftm = = =2764.2N Ftm = 2764.2N

b = 23mm
mm = 0.8m = 0.8(2.5) = 2.07 mm = 2.07
= 174.175Mpa δb1= 174.175Mpa
= 139.342Mpa
Hence, δb1 = 174.175mpa < δbp = 180Mpa the design is safe
δb1= 139.342Mpa

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Psc = 1093Mpa

Pp = 887.68Mpa

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