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Unit-III Design of Straight and spiral bevel gears
Given data: Horse Power, Speed of the driver (or) driven, Speed ratio, Working life, working
life, Working conditions.
If speed ratio is not given it can be selected from T4.P.8.3.
Design Procedure:
Step 1) Select suitable materials for pinion and wheel from T7,P8.5
Write down the following for both the materials
 Heat treatment assumed Surface hardness (The difference between the surface hardness
of pinion and wheel should be > 30HB, if the surface hardness of both the materials is <
350 HB. Pinion must be harder than wheel.
 σb for minimum module and [σo]
Step 2) Calculate Mt . Use equation on P 8.15. and Calculate also the speed ratio (always >1) if
not given calculate reference angle δ1 and δ1 (Refer T31, P 8.39)
Step 3) Assume the pressure angle if not given. Usually it is 200.

(FOR SPIRAL BEVEL GEARS : Assume pressure angle and spiral angle ß
also, if it is not given. Refer P 8.1)
Step 4) Initially assume Kd K value (Refer P 8.15) & ,

Calculate the design torque [Mt] = KdKMt
Step 5) Determination of minimum cone distance(C.D)
a) Determine Eeq = E from T9, 8.14, based on the selected materials.
b) Select Ψy from T13, P 8.15.

Use Table no 11 to select recommended Value
c) Using equation 1.3 in T8 P 8.13, Calculate the minimum cone distance‘R’. Use
[σc] of weaker material.
Step 6) Determination of minimum average module
a) Assume Z1 = no. of teeth on pinion (minimum 18)
b) Select ψ m from T12, P 8.14.

c) Select from factor Yv from T18, P 8.18 ,
under the column x = 0 corresponding to Zv = Z1/cosδ1. (For spiral bevel
gears: Select form actor,corresponding to Zv = Z1/ cos δ 1 . cos3 βav
d) Calculate minimum average module using the equation 2.3,in T8, P

8.13 use[σb]of weaker material. Calculate mt the transverse module. Use T31,
P 8.38 (For spiral bevel gears: Use equation 2.4). Calculate
normal module mn referring to T31, P 8.38).
e) Round off the transverse module to standard value, referring to T1, 8.2(Round
off the normal module mn standard value in the case of Spiral bevel gears).
Step 7) Determination of the dimensions of the pinion & wheel
a) Determine Z2 so that Z2 / Z1 = i.
b) Determine the cone distance R’ (T31, P 8.39)
If R’ >= R (minimum C.D already calculated) ,take R’ as the final cone distance.
If R’< R , increase module (OR) Z1& Z2 so that R’>= R.
c) Calculate d1& d2 , the reference diameter of pinion and wheel respectively

(T26 , P 8.22).
d) Calculate b (width of the gear wheel). Refer T31, P8.38.
Checking the design
Step 1) Corresponding to b/d values , selected load concentration factor K

(T14 , P 8.15)
Step 2) Selection of dynamic load factor Kd
a) Calculate pitch line velocity V (Refer P 8.15
b) Select IS quality based on pitch line velocity from T2, P8.3.

c)Based on pitch line velocity and IS quality, select the dynamic load factor
Kd from T15 ,P8.16.
Step 3) Calculate the design torque [Mt] = Kd KMt
Step 4) Checking for surface compressive stress
a) Calculate σ0 using the equation 1.6, T8, P8.13.

b) If σc<= [σc] , the design is safe.
If σc>[σc], change’R (or) b and again calculate σ0 Repeat till σ0<=[σ0]
c) If ‘R’ is changed , calculate again Z1 & Z2 and finalize R.
Step 5) Checking for bending of pinion tooth
a) Using the immediately previous values of R & b, Calculate σb using the

equation 2.8 in T8, p 8.13.(For spiral bevel gear: Use equation 2.9).
b) If σb< = [σb] , the design is safe. If σb>[ σb],change again R , m or b and
again calculate σb. Repeat it till σb<= [σb]
c) If ‘R’ and module are changed, calculate again Z1 & Z2 and finalize the
cone distance.
Step 6) Checking the design for Plastic deformation and Brittle Crushing
(i) Under Surface contact stress (for both pinion wheel)
a) Determine [σc] max. Refer T24, P 8.21

b) Calculate σ0 using the immediately previous values of R & b.
c) Calculate σ0 max using the equation 8.1, P 8.21.
d) If σ0 max <=[σc]max, the design is safe. Otherwise increase R or b, calculate σc and again
calculate σcmax. Repeat till σc max <=[σc] max
(ii) Under bending (check for both pinion and wheel)
a) Determine [σb]max . Refer T25, P 8.21.
b)Calculate σb Using the immediately previous values of R, m and b.
c) Calculate σb max, Using equation 8.2 P 8.21.
d) If σb max <=[σb]max , the design is safe . Otherwise increase R, m or b , calculate σb and again
calculate σbmax .Repeat till σb max<= [σb] max.
List out the following proportions of the gear drive
Cone distance =R=
Transverse Module = mt =
(Normal module , m, for spiral bevel gears)
Gear ratio =i=
Face width = b=
Spiral angle (FOR SPIRAL BEVEL GEARS) =β =
Pinion
Material =
No. of teeth = Z1 =
Reference diameter = d1 =
Tip diameter = da1=
Wheel
Material =
No. of teeth = Z2 =
Reference diameter =d2=
Tip diameter =da2=
GEAR E
1. PROBLEMS
1. Design a straight bevel gear speed reducer to transmit 40 KW with transmission ratio of 5:1, The
pinion rotates at 900 rpm and the operation is to be continuous. List out the important dimensions
the gear drive.
2. Design a straight bevel gear speed reducer to transmit 10 HPat 1440 rpm of pinion. Gear Ratio is
3. Two spiral bevel gear speed reducer of speed ratio 2 . The wheel is supported on both sides and th
pinion is overhanging .The input is from a 20KW electric motor running at 950 rpm to machine
that imposes moderate shook. Let Z1 = 20 Design the bevel gears and list out the important
dimension of the gear drive.
4. A pair of spiral bevel gears is used to transmit 12 HP rpm of pinion = 1200, rpm of gear = 420 ,
minimum number of teeth on pinion =20. Design the gear drive . Any required data may be suitab
assumed.

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Unit-III Design of Straight and spiral bevel gears

Write down the following for both the materials

Step 3) Assume the pressure angle if not given. Usually it is 200.

Step 4) Initially assume Kd K value (Refer P 8.15) & ,

Step 5) Determination of minimum cone distance(C.D)

a) Determine Eeq = E from T9, 8.14, based on the selected materials.

b) Select Ψy from T13, P 8.15.

Step 6) Determination of minimum average module

a) Assume Z1 = no. of teeth on pinion (minimum 18)

b) Select ψ m from T12, P 8.14.

d) Calculate minimum average module using the equation 2.3,in T8, P

Step 7) Determination of the dimensions of the pinion & wheel

b) Determine the cone distance R’ (T31, P 8.39)

c) Calculate d1& d2 , the reference diameter of pinion and wheel respectively

d) Calculate b (width of the gear wheel). Refer T31, P8.38.

Checking the design

Step 1) Corresponding to b/d values , selected load concentration factor K

Step 2) Selection of dynamic load factor Kd

a) Calculate pitch line velocity V (Refer P 8.15

b) Select IS quality based on pitch line velocity from T2, P8.3.

a) Calculate σ0 using the equation 1.6, T8, P8.13.

Step 5) Checking for bending of pinion tooth

a) Using the immediately previous values of R & b, Calculate σb using the

(i) Under Surface contact stress (for both pinion wheel)

a) Determine [σc] max. Refer T24, P 8.21

(ii) Under bending (check for both pinion and wheel)

a) Determine [σb]max . Refer T25, P 8.21.

b)Calculate σb Using the immediately previous values of R, m and b.

c) Calculate σb max, Using equation 8.2 P 8.21.

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