BEVEL GEARS

INTRODUCTION
 Bevel gears are used to transmit motion between two intersecting axes shafts.
 The pitch surface of a bevel gear is a frustum of cone, the teeth are placed on the cones
forming a bevel gear
 The pitch cones, when extended, meet at a common point called the apex, which is the
point of intersection of the shaft axes.
 The teeth of the bevel gears may be straight or spiral
 The teeth of straight bevel gears are straight which converge into the common apex.
 The size of the bevel gear tooth (thickness and height) decreases towards the apex of the
cone.
 Although the bevel gears are usually made for a shaft angle of 90 0, they can be produced
for almost any shaft angle
 The bevel gears are inherently non-interchangeable
 Straight bevel gears are easy to manufacture and design
 Straight bevel gears are not suitable for high speed applications and the maximum
peripheral speed should not generally exceed 3 m/s and when they are precision ground
they can be used upto 10 m/s
INTRODUCTION
 COMPARISON

Sr. Property Straight Bevel Gear Spiral Bevel Gear

No.
1. Tooth appearance The elements of the tooth of the straight While the elements of the tooth of the spiral
bevel gears are straight lines which converge bevel gears are curved.
into a common apex point.
2. Form of tooth Involute profile is used for the form of tooth Involute profile is used for the form of tooth of
of Straight Bevel Gears. Spiral Bevel Gears.
3. Ease of Design and Straight Bevel Gears are easy to design and Spiral Bevel Gears are difficult to design and
Manufacture cheaper to manufacture and give reasonably costly to manufacture, as they require specialized
good service when properly mounted. and sophisticated machinery for their
manufacture.
4. Performance Due to direct contact Straight Bevel Gears Spiral Bevel Gears have a smooth teeth
create noise at high speed conditions. So engagement (more teeth are in contact
these gears are used for small applications simultaneously) which facilitates a smooth and
where smoothness and quietness are not quite operation, even at high speeds. (Peripheral
primary requirements. (Maximum peripheral Speeds can be from 11 m/s to 35 m/s depending
speed should not exceed 3 m/s. When the upon the kind of surface finish).
gears are precision ground they can be used
at speeds up to 10 m/s)
5. Strength Straight Bevel Gears have comparatively Spiral Bevel Gears have better strength and
less strength. hence are used for high speed-high power
transmission.
6. Interchangeability Bevel Gears straight or spiral are not interchangeable and are always designed in pairs.
7. Size of the tooth The size of the Straight Bevel Gear tooth (thickness and height) decreases towards the apex of
the cone.
 TERMS USED IN STRAIGHT BEVEL GEARS
 Pitch Cone:
Pitch cone is the imaginary cone (or frustum of cone) which by pure rolling motion
transmits the same motion as by Bevel Gears.
 Pitch Surface:
It is the surface of the pitch cone.
 Pitch Line:
It is the line lying in the surface of an imaginary cone
 Cone Centre:
It is the apex of the pitch cone or it is the point where the axes of the two mating gears
intersect each other
 Pitch Circle Diameter (d):
It is the diameter of the pitch circle at the large end of the teeth
 Cone Distance (A0):
It is the length of the slant height (or generator) of the imaginary cone

2 2
 dp  d 
Ao      g 
2 2
TERMS USED IN STRAIGHT BEVEL GEARS
 TERMS USED IN STRAIGHT BEVEL GEARS
The dimensions of the bevel gear are always specified and measured at the large end of
the tooth
The addendum (= 1 module), dedendum (= 1.2 module), and the pitch circle diameter are
specified at the large end of the tooth
Pitch Angle (γ):
The angle made by the pitch line with the axis
of the gear is called as the pitch angle.

The pitch angle for the pinion is denoted by γp and  dg 

 
tan γ g    
that of gears is denoted by γg. 2 dg zg
  Gear Ratio (G)
 dp  dp zp
 
 2
Generally the gear axis of the pinion and gear
are at 900 to each other.
 dp 
Hence, γp + γg = 900.  
tan γ p    
2 dp zp 1
 
 d g  d g z g Gear Ratio (G)
 
 2
 TERMS USED IN STRAIGHT BEVEL GEARS
 Back Cone:  dg   dp 
    d
 
The back cone is an imaginary cone
cos γ g   2 
and cos γ p   2 
or cos γ   
2
and its elements are perpendicular to rbg rbp rb
the elements of the pitch cone.
 Back Cone Radius (rb):   dg     dp    d 
         
   
rbg      and rbp      or rb     
It is the length of the slant height (or 2 2 2
cos γ g cos γ p  cos γ 
generator) of the back cone.      
     
   
The back cone radius for pinion is
denoted by rbp and that of gear is Ao
Face Width  b  or 10 times module (10m)
denoted by rbg. 3
Whichever is smaller
 Face Width (b):
It is the length of the gear tooth measured
along the slant height (generator) of the cone
(or frustum of cone) of the bevel gear
 TERMS USED IN STRAIGHT BEVEL GEARS
 Mean Radius (rm):  dp   b sin γ p 
It is the pitch radius of the bevel gear at the midpoint r   
mp  2   2 
along the face width of the teeth.    
and
The mean radius for pinion is denoted by rmp and
 dg   b sin γ g 
  
that of gear is denoted by rmg. r
mg  2   2 
   
In general,
 d   b sin γ 
r  
m 2  
2 
 FORMATIVE OR VIRTUAL NUMBER OF TEETH (z’)
 Formative or Virtual Number of Teeth (z’):
Bevel Gear is kinematically equivalent to an imaginary spur gear in a plane
perpendicular to the tooth at the large end.
The pitch circle radius of this imaginary spur gear is equal to the back cone radius ‘rb’
and module is equal to ‘m’.
This imaginary spur gear is termed as an Equivalent Spur Gear or Virtual Spur Gear
or Formative Spur Gear.
The practice of characterizing the size and shape of bevel gear teeth as those of an
imaginary spur gear appearing on the developed back cone corresponds to what is
known as Tredgold’s Approximation.
The number of teeth z’ on this Equivalent Spur Gear is known as “Virtual or Formative
Number of Teeth”.
 FORMATIVE OR VIRTUAL NUMBER OF TEETH (z’)
 Formative or Virtual Number of Teeth (z’):
Pitch Circle Diameter of an Equivalent Spur Gear, mm 2rb
z'  
Module of an Equiavalen t Spur Gear, mm m
 dp   dp 
2   
 2 cos γ 
 
p 
   
2 rbp dp m zp
z 'p  
m m m cos γ p cos γ p cos γ p
Similarly,
 dg   dg 
2   
 2 cos γ 
 
g 
   
2 r d m zg
z 'g  
bg g

m m m cos γ g cos γ g cos γ g

z
In general, z' 
cos γ
 MINIMUM NUMBER OF TEETH TO AVOID
INTERFERENCE
 Minimum Number of Teeth to avoid Interference:
In order to avoid the interference in a bevel gear pair, it must be ensured that the
interference does not occur in an equivalent spur gear pair. It can be shown that the
general equation for minimum number of teeth required on the pinion, to avoid
interference is:
' 2 ha zp 2 ha 2 h a cos γ p
zp     z p 
2 2
cos γ p m sin φ 2
m sin φ m sin φ
2 h a cos γ p
z min 
2
m sin φ

ha = Addendum of the bevel gear, mm

 = Pressure angle
 FORCE ANALYSIS OF STRAIGHT BEVEL GEARS
 Force Analysis:
In force analysis of Straight Bevel Gears, it is assumed that the resultant tooth force
between two meshing teeth of bevel gears is concentrated at the midpoint along the face
width of the tooth and is at the mean radius rm. While the actual resultant tooth force
acts somewhere between the midpoint and the large end of the tooth, there is only a
small error in making this assumption.
Resultant Tooth Force (P)

Tangential Force (Ptm) Separating Force (Psm)

Radial Force (Prm) Axial Force (Pam)

FORCE ANALYSIS OF STRAIGHT BEVEL GEARS
 FORCE ANALYSIS OF STRAIGHT BEVEL GEARS
 Tangential Force (Ftm):
The tangential force is the useful component and is responsible for transmitting the
power. It is tangent to the pitch circle through the midpoint of the face width.
Ftm x rm = Mt (Tangential Force x Mean Radius = Torque Transmitted)
The tangential force acting on the driving member opposes the rotation of the driving
member whereas on the driven member it assists the rotation.

 Separating Force (Fsm):

It tends to separate the two gears. It is perpendicular to the pitch cone.
Fsm = Ftm x tan , where  is the pressure angle
 Radial Force (Frm):
Frm = Fsm x cos γ = Ftm x tan  x cos γ
Radial force component on Pinion = Frmp = Fsm x cos γp = Ftm x tan  x cos γp
 Axial Force (Frm):
Fam = Fsm sin γ = Ftm tan  x sin γ
Axial force component on Pinion = Famp = Fsm x sin γp = Ftm x tan  x sin γp
 DIRECTION OF FORCES
 Tangential Component:
The direction of tangential component of driving gear is opposite to the direction of
rotation.
The direction of tangential component of driven gear is same as the direction of
rotation.
 Radial Component:
Radial components of Gear and Pinion acts towards the centre of respective gears.
 Thrust Components or Axial Force:
Thrust component on pinion is equal and opposite of the radial component on the gear.
Thrust component on gear is equal and opposite to the radial component on the pinion.
 FORCE ANALYSIS OF STRAIGHT BEVEL GEARS
 Components of Force on the meshing bevel gear:
It is observed that for the shaft angle of 900, the radial force on the pinion is equal to the
axial force on the gear and the axial force on the pinion is equal to the radial force on
the gear.
Therefore for the shaft angle of 900,
Frmp = Famg
and
Famp = Frmg.
 BEAM STRENGTH OF STRAIGHT BEVEL GEAR
TOOTH
 Beam Strength (Fb OR Sb):
The beam strength of the straight bevel gear tooth is the maximum tangential load the
bevel gear tooth can transmit at the large end without bending failure.
Fb or Sb = m b b Y’ (1 – b/Ao)  Lewis Equation
where,
Fb or Sb = Beam strength, N
m = module at the large end of the teeth, mm
b = face width of the gear tooth, mm
= (Ao/3) or (10 module), whichever is smaller
b = permissible bending stress, N/mm2.
= Sut/3
Y’ = Lewis form factor based on Formative Number of Teeth (z’)
(z’ = z/cosγ)
Ao = pitch cone distance, mm
In the design of a bevel gear pair, it is necessary to decide the weaker member between
the gear and pinion in bending. The product (b x Y’) is the deciding factor.
 WEAR STRENGTH OF STRAIGHT BEVEL GEAR TOOTH
 Wear Strength (Fw or Sw):
The wear strength of the straight bevel gear tooth is the maximum tangential load the
bevel gear tooth can transmit at the large end without pitting failure.
Fw or Sw = b Q’ dp K/(cos γp)
But it is observed that only three fourth of the face is effective in transmitting load,
hence Fw or Sw = 0.75 b Q’ dp K/(cos γp)  Buckingham’s Equation
where,
Fw or Sw = Wear strength, N
b = face width of the gear tooth, mm
= (Ao/3) or (10 module), whichever is smaller
Q’ = Ratio factor 2 z 'g (z’ = z/cosγ)
Q'  '
z g  z 'p
dp = pitch circle diameter of the bevel pinion, mm
K = load stress factor, N/mm2

1 1 
2
c

σ sin  cos    
 Ep E g 
K
1.4
 WEAR STRENGTH OF STRAIGHT BEVEL GEAR
TOOTH
 Load stress factor (K):
The simplified expressions for load-stress factor K for different pinion and gear
material combinations and 200 pressure angle are as follows:
1. Steel pinion and steel gear:
2
 BHN  2
K  0.16   , N/mm
 100 
2. Cast iron pinion and cast iron Gear:
2
 BHN  2
K  0.21   , N/mm
 100 
3. Steel pinion and cast iron gear
2
 BHN  2
K  0.18   , N/mm
 100 
 EFFECTIVE LOAD ON STRAIGHT BEVEL GEAR
TOOTH
 Effective Load (Fteff):
The effective load on the straight bevel gear tooth is the total maximum tangential force
acting on the bevel gear tooth at the large end.
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Approximate estimation
K K
F teff  a m Ft
Kv
where, Ka = Service factor or application factor
Km = Load distribution factor or load concentration factor
Kv = Velocity factor
Ft = Theoretical tangential load, N
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Precise estimation
Fteff = Ka Km Ft + Fd
where, Fd = Dynamic Load, N
The dynamic load can be determined by Spott’s equation or
by buckingham’s equation
 DYNAMIC LOAD ON STRAIGHT BEVEL GEAR TOOTH
 Dynamic Load (Fd):
Spott’s Equation: (Dynamic Load in tangential direction)
e n p z p b ' rmp rmg
Fd  (for steel pinion and steel gear)
2530 rmp  rmg
2 2

e n p z p b ' rmp rmg

Fd  (for C.I. pinion and C.I. gear)
3785 r r
2
mp
2
mg

e n p z p b ' rmp rmg

Fd  (for steel pinion and C.I. gear)
3260 r  0.92 r
2
mp
2
mg

where, np = speed of the bevel pinion, r.p.m.

zp = number of teeth on bevel pinion
b’ = axial width of the gear blank
= b cos γp
rmp and rmg = mean radii of the pinion and gear respectively
e = sum of errors on the meshing teeth, mm
e = ep + eg the value of error depends on grade and tolerance factor, .
  m  0.25 d m
 DYNAMIC LOAD ON STRAIGHT BEVEL GEAR TOOTH
 Dynamic Load (Fd):
Buckingham’s Equation:
In the final stages of gear design, when gear pair dimensions are known as well as
gear pair teeth error are specified, the dynamic load can be more precisely
determined as an incremental load by using Buckingham’s equation for dynamic
load.
The Buckingham’s equation for the dynamic load in the tangential direction is
given by:
21 V (bC  Ftmax )
Fd 
21 V  bC  Ftmax
where, V = pitch line velocity at the large end of the tooth, m/s
b = face width of the gear, mm
C = deformation factor or dynamic factor, N/mm, C  k e  Ep E g 
 
Ep and Eg = modulii of elasticity of bevel pinion and E
 p  E g

gear material respectively, N/mm . 2

e = sum of errors on the meshing teeth, mm

k = tooth form factor
= 0.111 for 200 full depth involute;
= 0.107 for 14.50 full-depth involute
 DYNAMIC LOAD ON STRAIGHT BEVEL GEAR TOOTH

 Dynamic Load (Pd):

Buckingham’s Equation:
21 V (bC  Ptmax )
Fd 
21 V  bC  Ptmax
where, Ftmax = Ks Kd Ft
Pt = theoretical tangential load, N
Ka = application factor or service factor
Km = load distribution factor or load concentration factor

The simplified expression for deformation factor ‘C’ for different pinion and gear
material combinations and 200 pressure angle are as follows:
C = 11500 e, N/mm (Steel pinion and steel gear)
C = 8900 e, N/mm (C. I. pinion and C. I. gear)
C = 10000 e, N/mm (Steel pinion and C. I. gear)

e = sum of errors on the meshing teeth, mm

e = ep + eg the value of error depends on grade and tolerance factor, .
  m  0.25 d m
 SAFETY OF STRAIGHT BEVEL GEAR TOOTH
 Safety against bending failure:
In order to avoid the bending failure, the beam strength of the bevel gear tooth must be
greater than the effective load between the meshing teeth.
Therefore,
Fb or Sb > Feff
Fb or Sb = Feff (fos)

 Safety against pitting or wear failure:

In order to avoid the pitting failure, the wear strength of the bevel gear tooth must be
greater than the effective load between the meshing teeth.
Therefore,
Fw or Sw > Feff
Fw or Sw = Feff (fos)