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Spiral bevel gears are bevel gears whose axes intersect, often at a 90-degree angle. The teeth are cut with a slight curve along their length and an involute profile. Although they can be considered a hypoid gear, they have no offsets.
Spiral bevel gears are often used to transmit power through a right-angle. They are well suited for heavy-duty applications and can be designed for high-speed operations. Relative to some of the alternative bevel solutions, they can reduce the cost of ownership by providing longer-lasting performance and minimal need for repairs or replacements
Due to the geometry of the gear teeth, spiral bevel gears are more compact relative to their load rating, as well as more efficient than other types of right-angle gears. AGMA (American Gear Manufacturers Association) and the other associations around the world, define gear standards which include a system for describing the quality of gears. Amarillo Gear Company’s gears and gearboxes are designed to meet or exceed AGMA standards for a given service factor. As the quality of a spiral bevel increases, the efficiency increases, noise produced decreases, heat generation is reduced and vibration from their operation is lessened. Under the right conditions, a higher quality spiral bevel gear set can reach 99% efficiency.
Summary of Benefits of using Amarillo Gear Company’s Spiral Bevel Gears:
Higher Efficiency – The calculated efficiency of our spiral bevel gear sets are 96% to 98%, which is greater than that of other types of right-angle gear sets. This means more of the power from the prime mover is used to perform work and not generate heat. (The efficiency depends on the quality number, ratio, duty cycle, and other factors.)
Greater Power Density – Spiral bevel gears are more compact for their rated power than the other types of right-angle gears.
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.
Minimal Vibration – The shape of the spiral bevel gear teeth allow the gears to engage each other gradually and smoother than some of the alternative options. Therefore, a spiral bevel gear set will generate less vibration than other right-angle bevel gear sets with the same rating and similar finishing of their teeth.
Less Heat – The greatest source of power loss (efficiency) in a bevel gear set is from heat generated by the interaction of the gear teeth. The lower relative heat reduces the need for cooling of the oil and improves the operating life of the lubrication.
Higher Torque – A spiral bevel gear has more surface area in contact than a straight or zerol 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.
Better Life – By distributing the load over a larger area, the spiral bevel gear will result in a relatively lower contact stress in the gear teeth and lower bending moment at their root. This provides the spiral bevel with a longer design life (pitting and bending) than the other types of right-angle bevel gears of the same size.
Higher Speed – The higher quality spiral bevel gears can be operated at relatively high speeds.
Amarillo Gear has been designing and manufacturing gears for 90 years, in Amarillo, Texas. All gear processing is in-house including gear blanking, tooth generation, heat treating, and gear finishing. The greatest volume of our gears are used in our Pump Drives and Cooling Fan Drives. We also provide open gearing for industrial applications that include roller mills, cone crushers, marine transmission systems, off-highway transmissions, bow thrusters, and drill rigs.
All gear processes are “in-house” and controlled by internal quality processes which are certified by LRQA to ISO 9001:2015 standards. Many sizes and ratios are in stock for immediate delivery. We will either manufacture your design, reverse engineer or create a new design to meet your large diameter spiral bevel gear application.
If you’re in need of bevel gears, or you’re ready to learn more, contact Amarillo Gear Company today!
Spiral bevel gears are used in situations where the axis of rotation of a shaft must change direction. An example of this is a car differential where the rotating prop shaft is turned through 90° to drive the wheels - or as part of a large actuation mechanism like our screw jack powered systems.
Ideally this situation would transmit the required torque with maximum efficiency whilst producing minimum noise and vibration with a system that occupies minimum space at the required ratio reduction. The various bevel gear systems have their advantages and disadvantages and compromises are needed. An alternative to a bevel gear system, if the requirements allow, could be a worm drive (or worm gear set).
It is not a rule but bevel gear axes are commonly mounted at 90° to each other.
Straight Cut Bevel Gears
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The axes of straight and spiral bevel gear systems, if extended, intersect i.e. their axes are on the same plane.
The intersect of a bevel gears pitch surface with its axis is called the pitch apex. With a mating gear pair, their individual pitch apexes should be made to intersect in order for appropriate teeth engagement.
If maximum efficiency is required, straight and spiral bevel gears are most appropriate because they transmit load through rolling contact of the teeth resulting in little loss through friction.
Straight cut bevels are however relatively noisy since the tooth flank does not contact gradually as per helical cut gears.
Straight cut bevel gears are generally used in low speed applications where gear ratios of 1:1 to 5:1 are suitable.
Bevel gears with shafts at 90° each other and with the same number of teeth (1:1 gear ratio) are called Mitre Gears.
Spiral Bevel Gears
A spiral bevel gear has teeth cut in helical form with the pitch surface being conical.
This results in a reduction in noise and vibration through the gradual engagement of spiral teeth with the contact starting at one end of a gear tooth and progressively spreading across the whole tooth flank.
Typical gear ratios are 1:1 to 5:1.
The axes of a spiral bevel system are on the same plane.
Straight cut and spiral bevel gears offer relatively high efficiency due to the rolling contact between gear teeth.
Hypoid Bevel Gears
These are similar in appearance to spiral bevel gears and again have a helical tooth form. However, the pitch surface is a hyperboloid and the axes of the gear system do not intersect. This axial offset places a hypoid gear set geometry between that of a worm and a bevel gear set and therefore displays a combination of their characteristics. I.e. like a worm gear set it can transmit a large torque and, like a bevel gear set, it can run very smoothly with little noise or vibration. The more closely it resembles a bevel gear set, the higher the efficiency due to less losses through a lower sliding contact between the teeth. The positioning of the hypoid gear implies that multiple teeth mesh simultaneously thus sharing the load over a larger surface area and allowing for a greater transfer of torque.
Hypoid gear systems are often used in the differential of a truck where the requirement for the transmission of a large torque suggests a worm gear set, but at the same time the requirement to maximise the efficiency and smoothness necessitates a spiral bevel gear.
With car differentials, due to the emphasis being placed on fuel economy and smoothness, there is an argument for the utilisation of spiral bevel gears. Practically however, the gear sizes required in order to transmit the required torque may result in too large a gear system that impedes on the required ground clearance and therefore a hypoid gear system is required.
Hypoid gears can offer large gear reductions with ratios in the range 3:1 to more than 400:1.
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