Spiral Bevel Gears (helical bevel gear)

Spiral Bevel Gears (Helical Bevel Gear)

A spiral bevel gear is a bevel gear with helical teeth. The spiral design produces less vibration and noise than conventional straight-cut or spur-cut gear with straight teeth. This is mainly applied in a vehicle differential, where the drive directly from the drive shaft must be turned 90 degrees to drive the wheels.
A spiral bevel gear set should always be replaced in pairs, i.e., both the left-hand and right-hand gears should be returned together since the gears are manufactured and lapped in pairs.

Spiral Bevel Gear Advantages and Disadvantages

Advantages of Spiral Bevel Gear:

1. Higher Efficiency – The calculated efficiency of our spiral bevel gear sets is 96% to 98%, which is greater than that of other right-angle gear sets. (The efficiency depends on the quality number, ratio, duty cycle, and other factors.) this means more power from the prime mover is used to perform work and not generate heat.

2. Greater Power Density – Spiral bevel gears are more compact for their rated power than the other right-angle gears.

3. Smaller Space Claim (volume) –Their higher power density means the gearboxes that use spiral bevel gears can be designed to be smaller than transmissions that do not incorporate them. This results in lower weight, less space, and lower overall cost.

4. Minimal Vibration – The spiral bevel gear teeth’ shape allows the gears to engage each other gradually and smoother than some alternative options. Therefore, a spiral bevel gear set will generate less vibration than different right-angle bevel gear sets with the same rating and similar finishing of their teeth.

5. Less Heat – The most significant source of power loss (efficiency) in a bevel gear set is heat generated by the interaction of the gear teeth. The lower relative heat reduces the oil’s need for cooling and improves the lubrication’s operating life.

6. Higher Torque  – A spiral bevel gear has more surface area in contact than a straight or zero bevel for the same pitch diameter. The larger contact area means more power can be transmitted without exceeding the allowable stress of the alloy steel.

7. Better Life – By distributing the load over a larger area, the spiral bevel gear will result in relatively lower contact stress in the gear teeth and a lower bending moment at their root. This gives the spiral bevel a longer design life (pitting and bending) than the other types of right-angle bevel gears of the same size.

8. Higher Speed – The higher-quality spiral bevel gears can be operated at relatively high speeds.

Disadvantages of Spiral Bevel Gear:

1. High costs.
2. The spiral bevel gear is manufactured in pairs. For maintenance and repair, both gears must be replaced.
3. To achieve high efficiency, spiral bevel gear sets must be positioned exactly, so the shafts must be adjusted very precisely.
4. Spiral bevel gears are not recommended for high-speed reduction. At high speed, a spiral bevel gear unit generates noise.

Difference Between Spiral Bevel and Hypoid Gear

Spiral bevel gears are a variation of straight bevel gears. They have curved oblique teeth on which contact starts at one end of the tooth and progresses smoothly to the other. They produce less noise and vibration when compared to the straight teeth of a straight bevel gearbox. A spiral bevel gear has a 10:1 ratio range. Like the straight bevel gear, a spiral bevel gear efficiency is approximately 96% efficient per stage.
A hypoid gear is a type of spiral bevel gear, with the difference being that hypoid gears’ axes are in parallel planes but do not intersect. In other words, the axes of the hypoid gear are offset. The shape of a hypoid gear is hyperbolic; the shape of a spiral bevel gear usually is conical. A hypoid gear has a 25:1 ratio range. A hypoid gear set, in this ratio range, is approximately 90% efficient per stage.

Spiral Bevel Gears	Hypoid Gear

Spiral Bevel Gear Applications

1. Bevel gears are utilized in different applications, which range from the aerospace sector (high-velocity straight and spiral bevel gears, particular steels and functions, air pre-heater, etc.) to the mining applications (stacker and scoop actuators, wheeled excavators, dredges, conveyor belts, mill actuators, etc.).
2. They are also usual in sand mixers and conical mills, cooling towers, forklifts, ship actuators and propellers, pharmaceutical packaging machines, high-speed offset printing, polyethylene sheet production, automotive devices, and rail transmissions.
3. Angled bevel gears are employed for small spaces in robotics, whereas in ferrous metallurgy, they are utilized in vertical supports of the rolling mill.
4. In the case of food processing, bevel gears play an essential role in the processing and packaging of food and the instruments of can manufacturing.
5. When the speed and load are low, the transmission of power and motion between the two shafts is conducted by bevel gears.
6. In various automobile applications like vehicle differential drives, hypoid bevel gears are used.
7. For the critical mechanism of the hand drill, bevel gears are used.
8. Spiral bevel gears are used in sewing machines.

Mining: Bucket wheel excavators Stacker/reclaimer drives Dredger drives Mill drives Belt conveyors
Packaging & Food Processing Pharmaceutical Packaging Machines Can Production equipment Polythene Foil Production Specially designed gearboxes
Printing Offset high-speed printing gears
Railways Registered supplier to Indian Railways Overhaul/rebuild experience Diesel locomotive final drive and secondary final drives reverse engineering experience.

Materials Used to Make Bevel Gears

It is important to note that bevel gears are either straight-toothed or helical-toothed. The latter get further classified into the spiral and hypoid bevel gears. Gears with helical teeth are used for more incredible and smoother torque transmission. The basic requirements for materials that are used in the manufacturing of bevel gears are that they should be mechanically strong in bending and shear, they have to be resistant to chemical degradation and wear, and they should provide ease during the process of manufacturing.

Load Size is an Important Factor in the Selection of Materials

The materials that are used in the manufacture of bevel gears will vary depending on the size of the load. For high loads, ferrous metals are used. For example, grey cast iron can be used due to its low-cost characteristics and high resistance to wear. Forged or rolled carbon and alloy steel can also be used under high-speed and high-stress conditions. Non-ferrous metals such as aluminum and their alloys and non-metals like plastics are generally used in case of lighter loads.

The Manufacturing Process of Bevel Gears

The manufacturing process is divided into

1. Pre-forming the blank with or without the teeth.
2. Annealing of the blank when required. This is necessary in the case of cast or forged steel. Preparation of the gear blank is done to the needed dimensions using machining when teeth are produced or the pre-formed teeth are finished with the help of machining.
3. When required, surface or complete hardening of the machined teeth of the gear.
4. Finishing the teeth using grinding or shaving.
5. Inspecting the finished bevel gear.

Spiral Bevel Gear Cutting	Spiral Bevel Gear Grinding
Spiral Bevel Gear Milling	Spiral Bevel Gear Testing

Spiral Bevel Gear Manufacturers

We’ve been well-known as one of the leading spiral bevel gear manufacturers and suppliers in China for over ten years. Our factory offers customized spiral bevel gear in China at a competitive price. Welcome to contact us for wholesale service.

1. Provided highly precision spiral bevel gear.
2. Offers ODM & OEM services.
3. We also provide other types of gear.

Types of Gears

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