Helical Gears: Introduction

• In helical gears, the two meshing gears may be mounted on parallel

shafts. The teeth on helical gear are cut at an angle (helix angle) to the
gear axis.
• The helix angle usually ranges between 15º and 30º.
• Spur gears, are merely helical gears with a zero helix angle.
• Helix gears Carry more load than equivalent-sized spur gears
• The helix angle of helical gears is generally selected from the range
6,8,10,12,15, 20, 30 degrees.
• The larger the angle the smoother the motion and the higher speed
possible however the thrust loadings on the supporting bearings also
increases.
• A pair of parallel helical gears is shown in Fig. A 5 kW power at 720
rpm is supplied to the pinion A through its shaft. The normal module
is 5 mm and the normal pressure angle is 20°. The pinion has right-
hand teeth, while the gear has left-hand teeth. The helix angle is 30°.
The pinion rotates in the clockwise direction when seen from the left
side of the page. Determine the components of the tooth force and
draw a free-body diagram showing the forces acting on the pinion and
the gear.
 Helical Gears: Introduction
• Helical gears are classified as
Parallel helical gears
Crossed helical gears and
Herringbone gears
• All the helical gears generate thrust loads on the shafts because of inclined
teeth; hence, these must be taken care while designing the machines.
• THRUST load is load parallel to the shaft of the gear. It is produced by
helical gears because the helix angle, not the pressure angle. It is not
produced by spur gears, which have straight teeth that are parallel to the shaft
axis.
• RADIAL load is the load that tends to separate the gears. It acts
perpendicular to the shaft. This is what is produced by the pressure angle.
Both spur gears and helical gears produce this kind of load.
 Helical Gears: Introduction
• Double helical gears overcome the problem of axial thrust presented
by single helical gears by using two sets of teeth that are set in a V
shape.
• This arrangement cancels out the net axial thrust, since each half of the
gear thrusts in the opposite direction, resulting in a net axial force of
zero.
• However, double helical gears are more difficult to manufacture due to
their more complicated shape.
• To avoid axial thrust, two helical gears of opposite hand can be
mounted side by side, to cancel resulting thrust forces.
• Herringbone gears are mostly used on heavy machinery.
Helical Gears: Introduction
 Helical Gears: Introduction
• The angled teeth engage more gradually than do spur gear teeth causing
them to run more smoothly and quietly.
• Helical gears are highly durable and are ideal for high load applications.
• Helical gears can be used on non parallel and even perpendicular shafts,
and can carry higher loads than can spur gears.
• At any given time their load is distributed over several teeth, resulting in
less wear
• One of the disadvantages of these gears is the thrust which results along the
gear axis, which needs to be accommodated by using adequate thrust
bearings
• There is a greater degree of sliding friction between the teeth. This produces
greater wear during operation, and the need for lubrication systems.
 Helical Gears: Introduction
• The helical gear efficiency is lower due to the contact between its teeth, which
produces axial thrust and generates heat. A greater loss of energy reduces
efficiency.
• In helical gear, the teeth are not parallel to the gear axis. Because of this
arrangement of teeth in helical gears, have sliding contact between the teeth.
• Due to the sliding contact between the teeth of helical gear, axial thrust of gear
shaft also produces and also produce more heat. Thus the efficiency of helical
gear is less than that of the spur gear.
• Higher manufacturing cost than spur gears.
• For same tooth size (module) and equivalent width, helical gears can handle
more load than spur gears because the helical gear tooth is effectively larger
since it is diagonally positioned.
 Helical Gears: Terminologies
• The conventional representation of a pair of
helical gears on technical drawings is
illustrated in Fig.
• The hand of the helix is indicated by drawing
three thin continuous lines.
Helical Gears: Terminologies
 Helical Gears: Terminologies
• The angle Ψ is the helix angle.
• The transverse circular pitch (p) or circular pitch is measured on a
plane normal to the shaft axis (A-A plane).
• The normal circular pitch (pn )is the distance between corresponding
points of adjacent teeth, measured on a plane perpendicular to the
helix (B-B plane).
• The axial pitch (pa ) is the distance between corresponding points of
adjacent teeth, measured on a plane parallel to the shaft axis.
• For smooth transfer of load, the face width of helical gear (b) is
usually made at least 20% longer than the axial pitch (pa )
Helical Gears: Terminologies
Helical Gears: Terminologies
Virtual Number of Teeth
The intersection of the plane A–A and the pitch cylinder
(extended) produces an ellipse. This ellipse is shown by a
dotted line. The semi-major and semi-minor axes of this
ellipse
• The number of teeth z¢ on this imaginary spur gear is called the
virtual number of teeth. It is given by
 Gear Tooth Proportions
• In helical gears, the normal module mn should be selected from
standard values.
• The first preference values of the normal module are mn (in mm)
= 1, 1.25, 1.5, 2, 2.5, 3, 4, 5, 6, 8 and 10
• The standard proportions of the addendum and the dedendum are,
Addendum (ha) = mn
Dedendum (hf ) = 1.25 mn
Clearance (c) = 0.25 mn
The addendum circle diameter da is given by
Gear Tooth Proportions
Force Analysis
 Force Analysis
Direction of thrust force
• Select the driving gear from the pair
• Use right hand for RH-helix and left hand for LH-helix.
• Keep the fingers in the direction of rotation of the gear and the thumb
will indicate the direction of the thrust component for the driving gear.
• The direction of the thrust component for the driven gear will be
opposite to that for the driving gear.
• A pair of parallel helical gears is shown in Fig. A 5 kW power at 720 rpm
is supplied to the pinion A through its shaft. The normal module is 5
mm and the normal pressure angle is 20°. The pinion has right-hand
teeth, while the gear has left-hand teeth. The helix angle is 30°. The
pinion rotates in the clockwise direction when seen from the left side of
the page. Determine the components of the tooth force and draw a
free-body diagram showing the forces acting on the pinion and the
gear.
• A pair of parallel helical gears consists of an 18 teeth pinion meshing with a 45
teeth gear 7.5 kW power at 2000 rpm is supplied to the pinion through its shaft.
The normal module is 6 mm, while the normal pressure angle is 20°. The helix
angle is 23°. Determine the tangential, radial and axial components of the
resultant tooth force between the meshing teeth.
 Beam Strength
• Helical
  gear is considered to be equivalent to a formative spur gear,
• The formative gear is an imaginary spur gear in a plane perpendicular
to the tooth element.
• The pitch circle diameter of formative gear is d’, the number of teeth is
Z’ and the module mn.
• The beam strength of the spur gear is given by,
Sb=mbσbY (a)
This equation is also applicable to formative spur gear

Sb = (Sb)n = beam strength perpendicular to the tooth element

m = mn = normal module
b=
 Beam Strength
•Y  = Lewis form factor based on virtual
number of teeth Z’
Substituting these values in Eq. (a)
(Sb)n=
• In Fig. Sb is the component of (Sb)n in the
plane of rotation. Thus,
Effective Load
Effective Load
 Wear Strength
• The wear strength equation of
the spur gear is modified to suit
helical gears.
• For this purpose, a pair of helical
gears is considered to be
equivalent to a formative pinion
and a formative gear in a plane
perpendicular to the tooth
element.
• The wear strength of the spur
gear is given by,
Wear Strength
• A pair of parallel helical gears consists of a 20 teeth pinion meshing
with a 100 teeth gear. The pinion rotates at 720 rpm. The normal
pressure angle is 20°, while the helix angle is 25°. The face width is 40
mm and the normal module is 4 mm. The pinion as well as the gear is
made of steel 4OC8 (Sut = 600 N/mm2) and heat treated to a surface
hardness of 300 BHN. The service factor and the factor of safety are
1.5 and 2 respectively. Assume that the velocity factor accounts for the
dynamic load and calculate the power transmitting capacity of gears. T
Y for pinion can be taken as 0.3475
• Mt= {60*106*(KW)}/2(pi)np
• Mt= (Pt *dp)/2

• Sw= (Cs Pt *fs)/Cv

• Cv= 5.6/(5.6+

• Sw= (bQdp K)/Cos2(ψ) = 10318.58 N

• K= 0.16 (BHN/100)2 Q= 2Zg/(Zg+Zp) =1.667

=1.44
dp= (Zpmn ) / Cos(ψ) = 88.27

Sb= mn b σb y = 11120 N
• Mt= {60*106*(KW)}/2(pi)np
• Mt= (Pt *dp)/2
• A pair of parallel helical gears consists of 24 teeth pinion rotating at 5000 rpm and
supplying 2.5 kW power to a gear. The speed reduction is 4 : 1. The normal
pressure angle and helix angle are 20° and 23° respectively. Both gears are made
of hardened steel (Sut = 750 N/mm2). The service factor and the factor of safety are
1.5 and 2 respectively. The gears are fi nished to meet the accuracy of Grade 4.
• Take Y for pinion as 0.36 and deformation factor “C” can be taken as 11400
N/mm2
(i) In the initial stages of gear design, assume that the velocity factor accounts for
the dynamic load and that the face width is ten times the normal module. Assuming
the pitch line velocity to be 10 m/s, estimate the normal module.
(ii) Select the first preference value of the normal module and calculate the main
dimensions of the gears.
(iii) Determine the dynamic load using Buckingham’s equation and find out the
effective load for the above dimensions. What is the correct factor of safety for
bending?
(iv) Specify surface hardness for the gears, assuming a factor of safety of 2 for wear
consideration.
Given data : KW= 2.5 Zp=24, Np=5000 rpm i=4, Sut= 750 N/mm2, Cs=1.5
fs=2 Grade of mc= 4,

Sb= mnb = 900 m2n

Sb= Peff FS = (859.62*FS)/mn

={ (Cs Pt)/Cv} FS

Pt= (2Mt)/dp = 366.25/mn

Mt= 60*106*(KW) / 2*Pi*Np= 4774.648 N-mm

mn=1.5 mm
dp = 39.108 mm
dg= 156.44 mm
b= 15 mm
Sw= (bQdpK)/Cos2
• A pair of parallel helical gear consist of 30 teeth pinion rotating at
4000 rpm and supplying 10 KW power to a gear. The speed reduction
is 4.5:1. The normal pressure angle and helix angle are 200 and 450
respectively. Both gears are made of hardened steel (Sut= 600 N/mm2).
The service factor and factor of safety are 1.5 and 2 respectively
i) Assume that the velocity factor accounts for the dynamic load
and that the face width is ten times module. Assuming the pitch line
velocity to be 10 m/s, estimate the normal module
Ii) Select the first preference value of the normal module and
calculate the main dimensions of the gear
Iii) What is the correct factor of safety for bending
The form factor for Pinion can be taken as 0.4389
• The following data is given for a pair of
parallel helical gears made of steel:
• power transmitted = 20 kW
• speed of pinion = 720 rpm
• number of teeth on pinion = 35 number
of teeth on gear = 70
• centre distance = 285 mm
• normal module = 5 mm
• face width = 50 mm
• normal pressure angle = 20°
• Sut = 600 N/mm2
• surface hardness = 300 BHN
• grade of machining = Gr. 6
• service factor = 1.25 Calculate
• Y for pinion =0.3986
• C=11400 N/mm2
• (i) the helix angle; 22.920
• (ii) the beam strength; 19930 N
• (iii) the wear strength; 21495.64 N
• (iv) the static load; Pt=2792.19
• (v) the dynamic load by Buckingham’s
equation; 8049.29 N
• (vi) the effective load;
(CsPt+Pd)=11537.53
• (vii) the effective factor of safety against
bending failure; 1.73
• (viii) the effective factor of safety
against pitting failure. 1.86