Application, design, and manufacturing of conical involute gears for power transmissions

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Application, design, and manufacturing of conical involute gears for power transmissions

Börner, J. / Humm, K. / Joachim, F. / Yakaria, H.

Conical involute gears (beveloids) are used in transmissions with intersecting or skew axes and for backlash-free transmissions with parallel axes. Conical gears are spur or helical gears with variable addendum modification (tooth thickness) across the face width. Applications in power transmissions are more or less exceptional. ZF has implemented beveloid gear sets in various applications such as 4WD gear units for passenger cars, marine transmissions, gear boxes for robotics, and industrial drives. In this paper contact analysis and modifications (point contact and ease-off, flank modifications), load capacity and noise excitation and manufacturing simulation are lined out. It can be shown that the macro geometry and required flank topographies can be effectively designed for beveloid gear sets using special software. For beveloids, the equivalent cylindrical gear pair of the transverse section in the centre of the face width can be used for calculating the load capacity with commonly used standards. The load distribution across the face width should be verified via additional contact analyses and load pattern measurements. More precise analyses of the load capacity with detailed consideration of the load behaviour are possible with more advanced processes such as finite element method.