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Looking for a bevel gear set
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(Mechanical)
(OP)
4 Nov 12 09:42Hello,
I have an industrial machine application that calls for a spiral bevel set laid out exactly like a rear differential (plenty of clearance inside the crown gear, overhanging pinion). The application has a few sizes ranging 3.5:1 to 4.2:1 ratio, 8-12" crown diameter. Input speed is -rpm. Ideally we would use a Q10 or better, non-hypoid spiral bevel gearset but our production quantities (several dozen per year) make this very expensive.
Are there any automotive / agricultural / transportation ring and pinion combinations that have both commercial availability, quality, and highest efficiency?
I see the Dana 60 comes with a relatively low hypoid offset, will this translate into greater efficiency?
Thanks,
David
Replies continue below
(Mechanical)
4 Nov 12 12:49Some friends of ours restored a Ford school bus, for use as a camper/ party bus.It was great fun, having a party on the way to a party, etc.However, not even an electric guitar could drown out the howl from its axle.Any gearset that's not a hypoid may cause you to add a noise limit to your specs.
Mike Halloran
Pembroke Pines, FL, USA
(Publican)
4 Nov 12 17:33If you look at automotive, you will notice that truck rear ends tend to have the pinion closer to the centre line of the crown wheel or more in line with the axle axis.I believe this is for three reasons being:-1) A truck can have a high floor line with no real problems as ease of driver entry and low roof line for aero are not real considerations.2) A truck has less sensitivity to noise.3) A truck is more sensitive to power losses or drive line efficiency.Gear ratios tend to be shorter in a truck and power ratings tend to be higher.A very popular diff with hot rodders is the Ford 9". They are strong and reasonably efficient and quiet and very available in a wide range of ratios in the low to high 3s with around 3.5 to around 4.1 being common in things like F100s and around 3.0 to around 3.6 being common on passenger cars.Wereckers yards should have them by the dozen.
Regards
Pat
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(Mechanical)
(OP)
4 Nov 12 18:25I appreciate the suggestion. I'm pretty sure my customers don't want parts from a wrecker's yard. :)
I've been poking through the Dana line: 44, 60, 70, 80 and perhaps one of these is right for my applications. Many of these have crown gear diameters over 10" and pinion offsets of less than an inch. I think I might contact Dana engineering to see if this is a good way to go.
David
(Publican)
4 Nov 12 19:04You can still buy lots of new parts for Ford 9" at least from aftermarket and probably direct from Ford.I think concern or lack thereof for noise should be a major factor in your choice.
Regards
Pat
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(Electrical)
5 Nov 12 01:11Aren't new gearsets being currently made by some aftermarket people for early Ford (up through '48?) non-hypoid-bevel rearends? The fact that so many current-production race car quick-change rears still use this style ring/pinion- seems the gears must still be in production.
(Electrical)
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8 Nov 12 01:05Slight correction: I see that modern quickchange rears now almost universally use spiral-bevel ring/pinion gearsets, not straight-cut bevel as I thought. So they don't offer as much efficiency advantage (over hypoid) as I was thinking.
(Mechanical)
9 Nov 12 23:57geesamand,
Given the low production rates I agree that an aftermarket gear set would make most sense. Any rear axle from a light truck application will have a 8-12" ring gear (GMC Sierra has a 10.5 or 11.5 as well as the Dana models you mentioned).
As far as efficiency goes the spiral bevel is more efficient than the hypoid because it has almost no sliding contact. The bigger the offset the more sliding contact a hypoid will have and less efficient it will be. The advantage that the hypoid has is it creates less noise.
(Mechanical)
12 Nov 12 00:12You may want to check www.rexnord.com for possible production gear sets. Rexnord acquired the Falk product line (and production facilities) some time ago. Their products tend to be very durable but a bit heavy and expensive. If you are fabricating your own shafts and gear housings, you may be able to buy suitable gears at tolerable prices. The traditional Falk load ratings tend to be very conservative.
Valuable advice from a professor many years ago: First, design for graceful failure. Everything we build will eventually fail, so we must strive to avoid injuries or secondary damage when that failure occurs. Only then can practicality and economics be properly considered.
(Mechanical)
12 Nov 12 00:16Sorry, I forgot to mention that good spiral bevel gears are both very quiet and very efficient. Their efficiency is usually almost identical to that of comparable good helical gear sets.
Valuable advice from a professor many years ago: First, design for graceful failure. Everything we build will eventually fail, so we must strive to avoid injuries or secondary damage when that failure occurs. Only then can practicality and economics be properly considered.
(Electrical)
21 Nov 12 00:29I see in the Speedway Motors catalog that brand new ring/pinion gearsets are available for '35-48 Fords (ratios from 3.25 through 6.17). These are spiral bevel (not hypoid).
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Spiral bevel gear drives are an amazing technology. They allow you to transmit power around corners and, with our exceptional machining quality, make it easier to avoid the bounces and backlash that you may have experienced in other right-angle gearboxes. But when should you specifically spec a spiral bevel gear drive for your project?
What Are Spiral Bevel Gear Drives?
As a form of right-angle gearbox, a spiral bevel gear drive is a refined type of right-angle gearbox. Its mechanism allows for exacting control, reduced oscillation, and improved power transmission from one direction to another.
While any right angle gear can transmit force at a 90-degree angle, the design often exchanges precision for cost&#; resulting in imprecise indexing, increased noise, backlash, and other performance issues that are sure to impact efficiency and productivity. Since the gear teeth of a spiral bevel gear drive mesh diagonally, they can offer the raw power that comes with greater surface contact while producing smooth, accurate, repeatable motion.
Spiral Bevel Gear Drives: The Enemy of Backlash
When your application needs robust power with reduced risk and minimal backlash, spiral bevel gear drives provide you with superior results. If backlash were a comic book villain, spiral bevel gear drives would be the superhero ready to foil their evil plan and save the day. The shielded design of a MITRPAK spiral bevel gear drive also makes it an ideal solution for challenging environments, such as washdown processing or scenarios where contamination must be avoided from open drive systems such as food processing or pharmaceutical production.
The precision machining that is used in MITRPAK spiral bevel gear drives helps prevent backlash, which can affect your entire production line and increase the risk of damage or unanticipated failure in your other equipment. With backlash, you can expect to replace your right-angle gearboxes much more frequently, as well as having to undertake extensive maintenance to keep them operating. Backlash also causes a great deal of noise, making it difficult to work around and potentially hazardous on a busy production floor.
Spiral Bevel Gear Drives For Manufacturing Environments
Spiral bevel gear drives are incorporated in a wide range of challenging environments, and the unique adjustable locknut found in MITRPAK spiral bevel gear drives make it simple to undertake precise adjustment of your gearsets for the best possible operation. Instead of having to change out your right-angle gearboxes when you update equipment, you can simply make a few adjustments and go on with your process.
Other factors that you may want to take into account include whether the gearboxes are maintenance-friendly, with common fastener sizes that are easy to find. This makes even the more limited amounts of maintenance that are needed with these right-angle gearboxes fast and easy. Consider whether the spiral bevel gear drives can be customized to your specific operational requirements, including the housing, gear material, roll/dowel pins, locknuts, seals, shafts, bearings, and lubricants.
Is A Spiral Bevel Gear Drive Right For Me?
So, when are spiral bevel gear drives the best bet for your application? Ask yourself these questions:
Does the application have high power or torque requirements?
Is smooth motion or precision indexing critical to production activities?
Will the gearbox be exposed to caustic chemicals, frequent washdowns, or other challenging environmental factors?
Will the gearbox need to be accessed for maintenance or system repairs?
Is product contamination a concern?
By understanding where spiral bevel gear drives work well in your facility construction or upgrade plans, you can best incorporate these exceptional devices where they&#;ll matter most. If you&#;re ready to learn more about spiral bevel gear drives, the experienced professionals at MITRPAK are ready to help.
Is your application a perfect match for MITRPAK? Check out our free guide 5 Questions to Ask Before Buying Right Angle Gear Drives to learn more about the features and benefits of spiral bevel gear drives today.