F T ra n sf o F T ra n sf o

PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

HELICAL GEARS

The teeth of helical gears are cut in the form of a helix on the pitch cylinder. In spur gears, the
contact between meshing teeth occurs along the entire face width of the tooth, resulting in
sudden application of the load, which in turn, results in impact conditions and generates noise in
high speed applications. In helical gears, the contact between meshing teeth begins with a point
on the leading edge of the tooth and gradually extends along the diagonal line across the tooth.
There is a gradual pick-up of load by the tooth, resulting in smooth engagement and quiet
operation even at high speeds. Helical gears are used in automobiles, turbines and high speed
applications even up to 50 m/s. The magnitude of the helix angle is the same for the pinion and
the gear, however, the hand of the helix is opposite. A right hand pinion meshes with a left-hand
gear and vice versa.

TERMINOLOGY OF HELICAL GEARS

As shown in figure XX is the plane of rotation, while YY is a plane perpendicular to the tooth
elements. The distance A1-A2 is called the transverse circular pitch (p), which is measured in the
plane of rotation. The distance A1-C is called the normal circular pitch (p n), which is measured
in a plane perpendicular to the tooth elements. The normal pressure angle is always 20°. The
helix angle for Single-helical gear falls between 12° and 25°, and for double-helical gears it falls
between 20° and 45°. Helix angle – The helix angle is the angle between the axis (bore) of a
helical gear and an (imaginary) line tangent to the tooth. The helix angle is considered to be an
effective parameter to increase the contact ratio of a helical gear. Thus, it is possible to increase
the helical gear load carrying capacity, including the tooth bending stress and tooth contact
stress.

Compared to spur gears, they have the larger contact ratio and excel in quietness and less
vibration and able to transmit large force. A pair of helical gears has the same helix angle but the
helix hand is opposite.

When the reference section of the gear is in the normal plane, by tilting the hobbing tool, the spur
gear hobbing machine and hobbing tool can be used to produce helical gears. Because of the
twist of teeth, their manufacturing has the disadvantage of more difficult production.

The helical gears made by KHK can be classified into two groups by the reference section of the
gears being in the rotating plane (transverse module) and normal plane (normal module). If the
reference section is in the rotating plane, the center distance is identical to spur gears as long as
they are the same module and number of teeth. This allows for easy swapping with spur gears.
However, in this case, they require special hobbing cutters and grinding stones, leading to higher
production cost. On the other hand, if the reference section is in the normal plane, it is possible to
use spur gear hobbing tools and grinding stones. However, the same module and number of teeth
in spur gears no longer match the center distance of helical gears, and swapping becomes very
difficult. In addition, the center distance is usually not an integer.
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

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ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

Q: what are the advantages of helical gears over spur gears?

Ans: In helical gears, the contact between meshing teeth begins with a point on the leading edge
of the tooth and gradually extends along the diagonal line across the tooth. There is a gradual
pick-up of load by the tooth, resulting in smooth engagement and quiet operation even at high
speeds. Helical gears are used in automobiles, turbines and high speed applications even up to 50
m/s. Helical gears also have greater tooth strength and a higher load carrying capacity.

Disadvantages: a spur gear is more efficient if you compare it with a helical gear of the same
size, because helical gears have sliding contacts between the teeth which in turns produce an
axial thrust of gear shafts and generate more heat. So, more power loss and less efficiency.

Q. Why helical gears are stronger as compared to spur gears?

Ans: For same tooth size (module) and equivalent width, helical gears can handle more load than
spur gears because they have far more surface areas and due to the helical design, more teeth in
contact at the same time, spreading the load.

Q: what are herringbone and double helical gears?

Ans: Double helical gears and herringbone gears are the same type of gear, but those with a
groove in the center are called double helical gears, while those without a groove where the left
and right teeth meet in the center, are called herringbone gears.

Q: what is virtual number of teeth in helical gears?

Ans: The formative or equivalent number of teeth for a helical gear may be defined as the
number of teeth that can be generated on the surface of a cylinder having a radius equal to the
radius of curvature at a point at the tip of the minor axis of an ellipse obtained by taking a section
of the gear in the normal plane.

Mathematically, formative or equivalent number of teeth on a helical gear, TE = T / cos 3 where

T = Actual number of teeth on a helical gear, and = Helix angle. In helical gears, the teeth are
inclined to the axis of the gear.
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

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ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

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k

k
lic

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C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

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ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

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ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

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k

k
lic

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C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

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C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

D-19: Pair of helical gears is to transmit 17 kW. The teeth are 20° stub in diametral plane
and have a helix angle of 45°. The pinion runs at 10000 rpm and has 80 mm pitch diameter.
The gears has 320 mm pitch diameter. If the gears are made of cast steel having allowable
static strength of 100 MPa; determine a suitable module and face width from static
strength considerations and check the gears for wear, given S es = 620 MPa.

Given: P = 17 kW, dp= 80 mm, dg= 320 mm, NP= 10000 rpm, VR =320/80 = 4, Ng= 10000/4
=2500 rpm, v =3.14*80*10000/60000 =41.8 m/s, =20° stub involute profile, = 45°, d = 100
MPa, Ses = 620 MPa

1. Selection of gear/pinion for beam strength equation:- Since the same material is used for
the pinion and the gear, the pinion is weaker than the gear and selected for beam strength
equation.
2. Module
Module based on Lewis equation

Ft =P/v = 406 N
Cv = 5.55/(5.55+ v ) =0.46
Assume Cw = 1.15, k = b/mn =15
Assume Y = 3.14*0.135 = 0.42
From equation 19.50 mn = 1.26 say 2 mm
m = mn/cos( )= 2/0.707 = 2.8 mm
zp =d p/m = 29
zg =d g/m = 116
b= 15*mn = 30 mm
3. Checking for dynamic and wear load
Fb = d*b*mn*Yep
Zep = zp/cos3 )= 81.9
Yep =3.14*(0.175-0.841/z ep) = 0.51
Fb = 3103 N
Dynamic load =

Assume C = 118.7

Fd = 1874 N
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

Fb/Fd =1.65, design is safe

Wear strength

Q = 2*VR/VR+1 = 1.6

tan( n) = tan ( )*cos( )-----------------------19.38

n =14.7°
Sin( n) =0.25
Ep = E g =200,000 N/mm2
K = 0.69
Fw =5362 N
Fw>Fd, design is safe

D-12: Design a pair of helical gears to transmit 30 kW power at a speed reduction ratio of
4:1. The input shaft rotates at 2000 rpm. Take helix and normal pressure angles equal to
25° and 20, respectively. Both pinion and gear are made of steel. The number of teeth on
the pinion may be taken as 30. Use allowable stress for pinion dp = 55 MPa, pinion
harndess BHNp =340, allowable stress for gear dg = 40 MPa, gear hardness BHNg =300.

Given: P = 30 kW, VR =4:1, NP= 2000 rpm, VR = 4, Ng= 2000/4 =500 rpm, zp = 30, zg =VR*30
=120, n =20°, = 25°, dp = 55 MPa, BHNp =340, dg = 40 MPa, BHN g = 300.

1. Selection of gear/pinion for beam strength equation:- Since the material is used for the
pinion and the gear is different, gear/pinion will be selected based on product Y*
zep = zp/cos3 )= 40.2
zeg = z g/cos3 )= 161.1
Yp p = 3.14*(0.154-0.912/40.2)*55 = 22.6
Yg g = 3.14*(0.154-0.912/161.1)*40 = 18.6
So gear is weak and selected for beam strength equation
2. Module
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

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k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

Mt = 573248 N-mm
Assume Cw =1.15, v = 40 m/s, Cv = 5.55/5.55+ v = 0.46, k =15,
Cos( ) =0.9
zeg = zg/cos3 )= 161.1
Yeg =(0.154- 0.912/zeg)*3.14=0.46
From equation 19.50 we get
mn = 4.2 say 5 mm
m= mn/ Cos( ) =5.52 mm
dp = m*zp =166 mm
dg =664 mm
b = 15* mn =75 mm
3. Checking the gears for dynamic and wear load
Beam strength
Fb = dg*b*m n*Yeg = 6986 N

Actual velocity =3.14*d p*Np/60000 = 17.3 m/s

Ft = P/v =1726 N
C= 114.4 (steel-steel, table 19.12)
Fd = 8035 N design is unsafe
Use mn = 8 mm
m= mn/ Cos( ) =8.8 mm
dp = zp*m= 265 mm
dg =zg*m= 1060 mm
b = 120 mm
4. Checking the gears for dynamic and wear load
Beam strength
Fb = d*b*mn*Yeg
Fb = 17886 N
Dynamic load

Actual velocity =3.14*d p*Np/60000 = 27.7 m/s

Ft = P/v =1081 N
C= 114.4 (table 19.12)
Fd = 10465 N
Fb >1.25Fd design is safe
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

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k

k
lic

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C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

Wear strength

For safe design,

Q = 2*zg/(z g+zp) = 1.6
K= 0.16(BHNp/100)2 = 1.84
Fw = 114547 N,
Fw > Fd, design is safe

Example. A helical cast steel gear with 30° helix angle has to transmit 35 kW at 1500
r.p.m. If the gear has 24 teeth, determine the necessary module, pitch diameter and face
width for 20° full depth teeth. The static stress for cast steel may be taken as 56 MPa. The
width of face may be taken as 3 times the normal pitch. What would be the end thrust on
the gear?
Given: P = 35 kW, NP= 1500 rpm, =20° full depth involute profile, = 30°, d = 56 MPa, b =
3p n = 3*3.14mn = 9.42 mn, k= 9.42

1. Selection of gear/pinion for beam strength equation:- only single gear is mentioned in the
statement, so same selected for beam strength equartion
2. Module
Module based on Lewis equation

Mt = 222930 Nmm
Assume Cw =1.15, v = 40 m/s, Cv = 5.55/5.55+ v = 0.46,
k = b/m n =9.42
Cos( ) =0.866
zep = zp/cos3 )= 36.9
Yep =(0.154- 0.912/zep)*3.14=0.4
From equation 19.50 we get
mn = 5.6 say 6 mm
m= mn/ Cos( ) =6.92 mm
dp = m*zp =167 mm
b = 9.42* mn =56.5 mm
3. Checking for dynamic and wear load
Fb = d*b*mn*Yep
Fb = 7710 N
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

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k

k
lic

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C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

Dynamic load =

V= 13.1 m/s

Ft = P/v = 2669 N

Assume C = 114.4 (steel on steel)

Fd = 7604 N

Fb/Fd =1.01, design is unsafe

Use new value of normal module

mn = 8 mm
m= mn/ Cos( ) =9.23 mm
dp = m*zp =222 mm
b = 9.42* mn =75.3 mm
Checking for dynamic and wear load
Fb = d*b*mn*Yep
Fb = 13707 N
Dynamic load =

V= 17.4 m/s

Ft = P/v = 2008 N

Assume C = 114.4 (steel on steel)

Fd = 7855 N

Fb/Fd =1.74, design is safe

Axial thrust Fa = Ft* Cos( ) = 1739 N (equation19.47)