1 SHANTILAL SHAH

GOVERNMENT ENGINEERING
COLLEGE.
• BRANCH : PRODUCTION ENGINEERING
• SUBJECT : DESIGN OF MACHINE ELEMENTS
• TOPIC : Proportions of bevel gears , Design of bevel
gear
• NO. : ENROLLMENT NO. : NAME
 (1) 150430125078 : PANDYA PANKAJKUMAR M.
 (2) 150430125080 : PARMAR HIRENKUMAR A.
 2 • BEVEL GEARS:

 Bevel gears are the gears where the axes of the two shafts
intersect and the tooth-bearing faces of the gears themselves
are conically shaped.
 Bevel gears are most often mounted on shafts that are 90
degrees apart, but can be designed to work at other angles as
well. The pitch surface of bevel gears is a cone.

 Mitre gears are a type of bevel gears that have equal

numbers of teeth. The shafts are positioned at right
angles from each other, and the gears have matching
pitch surfaces and angles, with a conically shaped pitch
surface.
 3
• STRAIGHT BEVEL GEARS • SPIRAL BEVEL GEARS
4
• APPLICATIONS OF BEVEL GEARS:
 Bevel gears are used in differential drives, which
can transmit power to two axles spinning at
different speeds, such as those on a cornering
automobile.
 Bevel gears are used as the main mechanism for
a hand drill. As the handle of the drill is turned in
a vertical direction, the bevel gears change the
rotation of the chuck to a horizontal rotation. The
bevel gears in a hand drill have the added
advantage of increasing the speed of rotation of
the chuck and this makes it possible to drill a
range of materials.
 5

• ADVANTAGES: • DISADVANTAGES:

• This gear makes it possible to • One wheel of such gear is designed to

change the operating angle. work with its complementary wheel and
no other.

• Differing of the number of teeth • Must be precisely mounted.

(effectively diameter) on each
wheel allows mechanical • The shafts bearings must be capable of
advantage to be changed. supporting significant forces.
 6 • DESIGN PROCEDURE FOR BEVEL
GEARS:
 From the requirements choose suitable materials for pinion
and gear, tooth profile and pressure angle are selected.
 Minimum cone distance,R can be determined by using
equation,
 7

 Average module mav can be calculated based on the

beam strength using the equation,
 8

Diameter of pinion,

Diameter of the wheel,

Recalculate cone distance,

Calculate the face width,

 9 Checking conditions:

Check for surface compressive stress using the

equation,

Check for bending stress using the equation,

Tabulate the results.

10 • Design of a shaft for Bevel Gears :
11 • Proportions for Bevel Gear :

The proportions for the bevel gears may be

taken as follows
1) Addendum, a = 1m
2) Dedendum, d = 1.2m
3) Clearance, = 0.2m
4) Working depth, = 2m
5) Thickness of tooth. = 1.5708m
Where m is the module
12
GEOMETRY AND TERMINOLOGY :

Bevel gear in mesh

• When intersecting shafts are connected by gears, the pitch cones (analogous to the
pitch cylinders of spur and helical gears) are tangent along an element, with their apexes at the

intersection of the shafts as in Fig.13.2 where two bevel gears are in mesh.

• The size and shape of the teeth are defined at the large end, where they intersect the back

cones. Pitch cone and back cone elements are perpendicular to each other.
13

Fig. 13.3 Bevel gear nomenclature

• The tooth profiles resemble those of spur gears having
pitch radii equal to the developed.

Zv1 = 2 πrb1 = Z1 ( 13.1)

p cosγ

Zv2 =
2 πrb2 = Z2 (13.2)
p cosγ

• where Zv is called the virtual number of teeth, p is the circular pitch of both the imaginary spur gears

and the bevel gears. Z1 and Z2 are the number of teeth on the pinion and gear, γ1 and γ2 are the pitch

cone angles of pinion and gears. It is a practice to characterize the size and shape of bevel gear

teeth as those of an imaginary spur gear appearing on the developed back cone corresponding to

Tredgold’s approximation.
 a) Bevel gear teeth are inherently non - interchangeable.

14 b) The working depth of the teeth is usually 2m, the same as for standard spur and
helical gears, but the bevel pinion is designed with the larger addendum ( 0.7

working depth).

a) This avoids interference and results in stronger pinion teeth. It also increases the

contact ratio.

b) The gear addendum varies from 1m for a gear ratio of 1, to 0.54 m for ratios of

6.8 and greater.

The gear ratio can be determined from the number of teeth, the pitch diameters or the

pitch cone angles as,

ω1 n1 Z2 d2
i= = = = = tanγ =cotγ (13.3)
ω 2 n 2 Z1 d1 2 1

Accepted practice usually imposes two limits on the face width

L
b 10m and b  (13.4)
3
Where L is the cone distance. Smaller of the two is chosen for design.

Fig. 13.4 Illustration of spiral angle

 The Fig.13.4 illustrates the measurement of the spiral angle  of a spiral bevel gear.

15 Bevel gears most commonly have a pressure angle of 20o, and spiral bevels usually

have a spiral angle  of 35o.

Fig.13.5 Zero bevel gears

The Fig.13.5 illustrates Zero bevel gears, which are having curved teeth like spiral

bevels. But they have a zero spiral angle.

Fig. 13.6 Comparison of intersecting and offset shaft bevel type gearings
16

(a) (b) (c)

(d) (e) (f)

Fig.13.7 Different types of bevel gears (a) Usual form, (b) Miter gears,

(c), (d), (e) Crown gear, (f) Internal bevel gear

13.3 FORCE ANALYSIS

Fig. 13.8 Gear tooth forces

17

Fig. 13.9 Gear and shaft forces

Fig. 13.10 Bevel gear - Force analysis

In Fig. 13.10, Fn is normal to the pitch cone and the resolution of resultant tooth force Fn

into its tangential (torque producing), radial (separating) and axial (thrust) components
 is designated F t , Fr and Fa respectively. An auxiliary view is needed to show the true

18 length of the vector representing resultant force Fn (which is normal to the tooth profile).

Fig. 13.11 Linear tooth force distribution

Resultant force Fn is shown applied to tooth at the pitch cone surface and midway along

tooth width b. It is also assumed that load is uniformly distributed along the tooth width

despite the fact that the tooth width is larger at the outer end.

dav =d-bsin (13.5)

πdavn
Vav = (13.6)
6000

1000W (13.7)
Ft=
v av

Where Vav is in meters per second, dav is in meters, n is in revolutions per minute, Ft is in

N and W is power in kW.

Fn = Ft /cosφ (13.8)

Fr = Fn cosγ = Ft tanφ co (13.9)

Fa = Fn sinγ = Ft tanφ sin (13.10)
 For spiral bevel gear,

19 Fr =
Ft
( tanφn cosγ
cosψ )
sinψ sinγ (13.11)

Fa = Ft ( tanφn sinγ ± sinψ cosγ ) (13.12)

Where or  is used in the preceding equation, the upper sign applies to a driving
pinion with right-hand spiral rotating clockwise as viewed from its large end and to a

driving pinion with left-hand spiral rotating counter clock-wise when viewed from its large

end. The lower sign applies to a left-hand driving pinion rotating clockwise and to

a driving pinion rotating counter clockwise. Similar to helical gears, φn is the pressure

angle normal measured in a plane normal to the tooth.

13.4 TOOTH BENDING STRESS

The equation for bevel gear bending stress is the same as for spur gears as shown

below:

F
σ b = t K vK oK m (13.13)
bmJ

Where, Ft =Tangential load in N

m = module at the large end of the tooth in mm

b = Face width in mm

J = Geometry form factor based on virtual number of teeth from Fig. 13.12 and 13.13.

Kv = Velocity factor, from Fig.13.14.

Ko = Overload factor, Table 13.1.

Km = Mounting factor, depending on whether gears are straddle mounted (between two
bearings) or overhung (outboard of both bearings), and on the degree of mounting

rigidity as shown in Table 13.2.

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Fig. 13.12 Number of teeth in gear for which geometry factor

J is desired, pressure angle 20o and shaft angle 90o

Fig.13.13 Number of teeth in gear for which geometry factor J is

desired, pressure angle 20o, spiral angle 35o and shaft angle 90o
21

Fig.13.14 Dynamic load factor, Kv

Table 13.1 -Overload factor Ko

Driven Machinery

Source of Uniform Moderate Heavy

power Shock Shock
Uniform 1.00 1.25 1.75

Light shock 1.25 1.50 2.00

Medium 1.50 1.75 2.25

shock
 Table 13.2 Mounting factor Km for bevel gears

22 Mounting type Mounting rigidity

Maximum to questionable
Both gears are straddle-
1.0 to
mounted
1.25

One gear straddle-

1.1 to
mounted; the other 1.4
overhung

1.25
to 1.5
Both gear overhung
13.6 PERMISSIBLE TOOTH BENDING STRESS (AGMA)

Fatigue strength of the material is given by:

σe = σ e ’ kL kv ks kr kT kf km (13.14)
Where, σ e’ endurance limit of rotating-beam specimen

kL = load factor, = 1.0 for bending loads

kv = size factor, = 1.0 for m < 5 mm and

= 0.85 for m > 5 mm

ks = surface factor, taken from Fig.13.15 based on the ultimate strength of the material

and for cut, shaved, and ground gears.

kr = reliability factor given in Table 13.3.

kT = temperature factor, = 1 for T≤ 120oC and more than 120oC, kT < 1 to be taken from

AGMA standards
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Fig.13.15 Surface factor, Ks

Table 13.3 Reliability factor Kr

Reliability factor R 0.50 0.90 0.9 0. 0. 9

999
5 9 9
9 9 0.9
Factor Kr 1.000 0.897 0.86 0.814 0.753 0.702
8
kf = fatigue stress concentration factor. Since this factor is included in J factor its value is

1.

km = Factor for miscellaneous effects. For idler gears subjected to two way bending, =
1. For other gears subjected to one way bending, the value is taken fromFig.13.16. Use

km = 1.33 for σut less than 1.4GPa.

Fig.13.16 Miscellaneous effects factor Km

 Permissible bending stress is given by

24 σ
[σ b ]= e
s
(13.15)

Hence the design equation from bending consideration is,

σb ≤ [σb ] (13.16)

Bevel gear surface fatigue stress can be calculated as for spur gears, with only two

modifications.

Ft (13.17)
σ H =C p K K K
bdI V o m

13.7 CONTACT STRESS:

1.23 times the Cp values given in the Table13.4 are taken to account for a somewhat

more localized contact area than spur gears.

Table 13.4 Elastic Coefficient Cp for spur gears, in (MPa)0.5

Pinion Material Gear material

s
(µ = 0.3 in all cases) Steel t iron Al Bro nze Tin Bron ze
Ca
Steel, E=307GPa 191 166 162 1
5
8
Cast iron, E = 131GPa 166 149 149 1
4
5
Al Bronze, E = 121GPa 162 149 145 1
4
2
Tin Bronze, E = 110GPa 158 145 141 1
3
7
25

Fig.13.17 Geometry factor I for straight bevel gear pressure angle 20o and shaft

angle 90o

Fig.13.18 Geometry factor I for spiral bevel gear pressure angle 20o, spiral angle

35o and shaft angle 90o

 Surface fatigue strength of the material is given by,

26 σsf = σsf’ KL KH KR KT (13.18)

Where σsf’ = surface fatigue strength of the material given in Table 13.7

KL = Life factor given in Fig.13.19

Table 13.7 Surface fatigue strength σsf (MPa) for metallic spur gear,
(107 cycle life 99% reliability and temperature < 120o C)

Material σsf (MPa)

Steel 2.8 (Bhn) – 69 MPa

Nodular iron 0.95 [ 2.8 (Bhn) – 69 MPa]

Cast iron, grade 20 379

Cast iron, grade 30 482

Cast iron, grade 40 551

Tin Bronze, AGMA 2C ( 11% Sn) 207

Aluminium Bronze (ASTM b 148 – 52) (Alloy 9C – H.T ) 448

Fig.13.19 Life factor KL

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KH is hardness ratio factor, K the Brinell hardness of the pinion by Brinell hardness of

the gear as given in Fig. 13.20.

KH = 1.0 for K < 1.2

KR = Reliability factor, given in Table 13.3.

Fig.13.20 Hardness ratio factor, KH

KT = temperature factor,

= 1 for T≤ 120oC based on lubricant temperature.

Above 120oC, it is less than 1 to be taken from AGMA standards.

Allowable surface fatigue stress for design is given by

[σH ] = σSf / s (13.19)

Factor of safety s = 1.1 to 1.5

Hence Design equation is:

σH ≤ [ σH ] (13.20)

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