Design of Machine Elements-II 18ME62

Module 3
BEVEL GEARS AND WORM GEARS
The bevel gears are used to transmit power at a constant velocity ratio between two shafts
whose axes intersect at a certain angle. The pitch surfaces for the bevel gear are frustums of
cones.

CLASSIFICATION OF BEVEL GEARS:

Classified depending upon the angles between the shafts and the pitch surfaces.

(i) Miter gears: when equal bevel gears (having equal teeth and equal pitch angles) connect
two shafts whose axes intersect at right angles as shown, then they are known as miter
gear.

(ii) 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.

(iii)Crown bevel gears: when 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 90 then it is known as a crown gear. The
crown gear corresponds to a rack in spur gearing as shown.

(iv) Internal bevel gears: when the teeth on the bevel gear are cut on the inside of the pitch
cone then they are known as inter bevel gears.

Note: The bevel gears may have straight or spiral teeth. It may be assumed, unless otherwise
stated that the bevel gear has straight teeth and and the axes of the shafts intersect at right
angle.

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Design of Machine Elements-II 18ME62

TERMS USED IN BEVEL GEARS:

A sectional view of two bevel gears in mesh is as shown. The following terms are
important from the subject point of view.

(i) Pitch cone: It is a cone containing the pitch elements of the teeth.

(ii) 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.

(iii) Pitch angle: It is the angle made by the pitch line with the axis of the shaft. It is denoted
by (i.e, 1 & 2)

(iv) Cone distance: It is the length of the pitch cone element. It is also called as a pitch cone radius.

pitch radius Dp/2 D /2

OP G

sinOp sinOp1 sinOp2

(v) Addendum angle: It is the angle subtended by the addendum of the tooth at the cone
centre. It is denoted by a. Mathematically addendum angle.

2h a1 Sin 1
tan a
d
1

2h a2 Sin 2

d2

(vi) Dedendum angle: It is the angle subtended by the Dedendum of the tooth at the cone
centre. It is denoted by d. Mathematically,

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Design of Machine Elements-II 18ME62

2h f 1 sin 1
tan d
d1

2h f 2 sin 2
d2
Where, ha1, ha2 = addendum of the pinion and gear respectively, mm hf1, hf2
= dedendum of pinion and gear respectively, mm

(vii) Face angle: It is the angle subtended by the face of the tooth at the cone centre. The
face angle is equal to the pitch angle plus addendum angle.

(viii) Root angle: It is the angle subtended by the root of the tooth at the cone centre. It is
equal to the pitch angle minus dedendum angle

(ix) Back cone: (Normal cone): It is the imaginary cone perpendicular to the pitch cone at
the end of the tooth.

(x) Crown height: It is the distance of the crown point C, from the cone centre O, parallel
to the axis of the gear. It is the denoted by C

(xi) Mounting height: It is the distance of the back of the boss from the cone centre. It is

(xii) Pitch diameter: It is the diameter of the largest pitch circle.

(xiii) Outside or addendum cone diameter: It is the maximum diameter of the teeth of the
gear. It is equal to the diameter of the blank from which the gear can be cut.
Mathematically outside dia ,

dO1 = d1 + 2ha1, Cos 1

dO2 = d2 + 2ha2, Cos 2

Proportions of Bevel gears:

The proportion for the bevel gear may be taken as

(i) Addendum: a = 1.0 m

(ii) Dedendum: d=1.2 m
(iii) Clearance = 0.2 m
(iv) Working depth = 2.0m
(v) Tooth thiknes = 1.5708

Formative or Equi

Ze = Z/Cos

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Design of Machine Elements-II 18ME62

STRENGTH OF BEVEL GEARS:

The strength of a bevel gear tooth is obtained in a similar way as discussed in the previous
articles. The modified form of the lewis equation for the tangential tooth load is given as
follows

1
y = lewis form factor based on formative or equivalent number of teeth

L = Slant height of pitch cone (or cone distance)

1 d2 d2
2 1 2

Where d1 and d2 are the pitch circle diameters on the larger diameter of pinion and
gears respectively

b L
(i) The factor i.e, may be called as bevel factor

(ii) For satisfactory operation of bevel gears the face width should be from 6m to 10 m. Also
ratio L/b should not exceed 3, (i.e., b L / 3)for this the number of teeth

in the pinion must not be less than 48

2
1 (vR)

(iii) The dynamic loads for bevel gears may be obtained in the same similar manner as
discussed for spur gears.
(iv) The static tooth load or endurance strength of the tooth for bevel gears is given by

1 L b
Fe e b my
L
The value of flexural endurance limit ( e) may be taken from table

(v) The maximum or limiting load for wear for bevel gears is given by

Fw D bQ k
1 e Cos
1

Where,
D1, b, Q, k, have usual meanings as discussed in spur gears except that Qe is based
on formative or equivalent number of teeth, such that,

Q 2 Ze 2

Ze 2 Ze 1

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Design of Machine Elements-II 18ME62

A pair of bevel gears to connect two shafts at right angles and transmit 9 kW. The allowable static
stress for pinion and gear materials may be taken respectively as 85 MPa and 55 MPa and brinell
hardness of 200 and 160. The speed may be assumed as 1200/420 and number of teeth may be
assumed as 21 for pinion and 60 for gear. Tooth profile may be taken as 20 full depth involute.
Check the design for dynamic and wear loads.

Given: s= 90 , P = 9kW = 9000W, Z1 = 21,Z2= 60, d1 = 85 MPa,

d2 = 55 MPa, N1 = 1200 rev/min, N2 = 420 rev/min, = 20 (full depth involute)
Find, module, and check the design for dynamic and wear loads,

Since, the shafts are at right angles, Therefore, pitch angle for pinion,

1 19.3
90
and the pitch angle for gear 2 1

2 70.7

W.K.T,

formative number of teeth for pinion

Ze Z1 21 .
1
cos 1 cos 19. 3

Z1
22 . 25
0 . 9438

e
1
22 . 25
Z
Z 2
60 60
e
and 2
cos 2 cos 70.7 0.3305
Z e2 181 .54

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Design of Machine Elements-II 18ME62

W.K.T.

for 20 full depth involute system tooth from factor

y1 0.154 0.912
For pinion 1 Ze
1

0 154 0.912 (0 154 0.0405) 0.11350

22 . 25
1
y 0 154 0.912
and for gear 2
181.54
0 .154 0 .00502 0 .14898
1
1 y 85 0.11350 9.6475
d 1
1
d2 y 2 55 0.14898 8.1939

Since the product, is less than therefore Gear is weaker, and thus

the design should be based on gear only.

W.K.T.

3
Ft P 10
v

.d2 N2 .mZ2 N2
Here
v
60 60
m 60 420
1320m mm / Sec
60

v 1.320m m / Sec

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Design of Machine Elements-II 18ME62

Now
3 3
F P 10 9 10 6818.18
t
v 1.320 m M

F 6818 .18 N
t m

Taking velocity factor

6 .1
Cv
6 .1 v

(taking into consideration that gears are very accurately cut and ground gears
having a pitch line velocity from 6 m/ sec to 20 m/sec)

6 .1
Cv 6 .1 1 .32 m
W.K.T,

Length of pitch cone element

L
d2 m 60
2 Sin 2 2 Sin 70 .7
m 60 31.78 m
2 0.9438

L = 31.78 m

Assuming the face width b = 1/3rd of the length of the pitch cone element L,
L 31.78 m
b 10.60 m
3 3

b=10.60 m

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Design of Machine Elements-II 18ME62

W.K.T,

The tangential tooth load on gear

6818.18 6.1
m 55 x 6.1 1.32 m x 10.60 m

31.78 m 10.60 m
x m x 1.4898
31.78 m

2
6818.18 1109 m
m 6.1 1.32 m

3
41590 + 8999 m = 1109 m

Solving this by hit and trial method we get, m = 4.58

m = 5.0 (Standard)

and b = 10.60 x m

= 10.60 x 5 = 53.0 mm

b = face width = 53.0 mm

Thus, d2 = m x 60 = 5 x 60 = 300 mm d1 = m

x 21 = 5 x 21 = 105 mm & L = 31.78

m = 31.78 x 5 = 158.9

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Design of Machine Elements-II 18ME62

Check for dynamic load

W.K.T,

Pitch line velocity

V = 1.320 m m/sec

= 1.32 x 5

v = 6.600 m / Sec

and tangential tooth load on the gear

Ft 6818.18 N
m

6818.18
5

Ft = 1363.63 N

From table the tooth error in action for first class commercial gears having module 5 mm is

e = 0.0555

Take K1 = 9.0 for 20 full depth teeth

3 2
and E1 = 210 x 10 N/mm and
3 2
E2 = 84 x 10 N/mm

C = dynamic factor depending upon machining errors

e
k1 (1/ E1 1 / E2 )

0.0555
9.0 1 1

3 3
210 10 84 10
3
6.166 10

6
(4.76 10 1.190 10 5
)

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Design of Machine Elements-II 18ME62

3
6.166 10
5
(0.476 1.190)10

3 5
6.166 10 10
1.666

2 1.666
6.166 10 370.1 N / m

C = dynamic factor = 370.1.N/m

W.K.T

Dynamic load on the gear

= Fd = Ft + Fi

k 3 v (cb Ft )
Ft
c F
k3 v b t

1363.63 20.67 6.6 (370.1 53 1863.63)

20.67 6.6 370.1 53 1363.63

1363.63 136.422 (19615.3 1363.63)

136.422 19615.3 1363.63

1363.63 136.422 20978.93

136.422 20978.93

2861987.588
1363.63
136.422 144.841

1363.63 2861987.588
281.263

= 1363.63 + 10175.485

Fd = 11539.115 N

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Design of Machine Elements-II 18ME62

2
en = for gear material of BHN = 160, is taken as 83.5 N/mm

Further, we know static tooth load or endurance strength of the tooth

= 83.5 x 53 x x 5 x 0.14898((158.9-53)/158.9)

= 83.5 x 53 x x 5 x 0.14898 x 0.666

FS = 6902.116 N

Since FS < Fd, the design is not satisfactory from the standpoint of dynamic load.

It is known that FS 1.25 Fd for steady loads

i.e., Fd dynamic load on gear must be reduced

i.e, by assuming for a satisfactory design against dynamic load, let us take the precision
gears (class III) having tooth error in action

e = 0.0150 mm
C = 100.02 N/mm

FD 1363.63 20.67 6.6 (100.02 53 1363.63)

20.67 6.6 100.02 53
1363.63

1363.63 136.422 (5300 1363.63)

136.422 5300
1363.63

1363.63 136.422 6663.63

136.422
6663.63

1363.63
136.422 6663.63
136.422 81.63

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Design of Machine Elements-II 18ME62

1363.63 909065.7319
281.052

= 1363.63 + 4169.0318

FD = 5532.66 N

From the above we see that by taking precision gear, FS is greater than FD, therefore, the
design is satisfactory from the standpoint of dynamic load

F 6902.166
here s 1.2475

FD 5532.66

(Hence, design is safe)

Check for wear load

2
For 180 BHN, es may be 617.8 N /mm normally steel for pinion and cost iron for gear of
200 & 160 , (Hence in the table take 180 & 180)

( ) 2
k = load stress factor es Sin 1 1
1.4 E1E2
2
(617.8) Sin 20 1 1
3 3
1.4 210 10 84 10

381676 x 0.342 1 2.5

3
1.4 210 10

130533.192 3.5

3
1.4 210 10
2
= 1.553 N / mm

2
k = 1.553 N / mm

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Design of Machine Elements-II 18ME62

and
Qe = ratio factor

2 Ze2 2 181.54

Ze2 Ze 22.25 181.54

363.08 1.78
203.79

W.K.T

Maximum or limiting load for wear

*
= FW = d1 b Qe K (*? For pinion, please explain)

= 105 x 53 x 1.78 x 1.553

Fw = 15397.70 N

Since, Fw is greater than FD the design is satisfactory from the standpoint of wear also.

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