2.

THEORETICAL BASIS

The contact stress calculus relation is established for the

gearing pole, based on the calculus assumptions for a
helical gear [3, 6], applied to the substitute (virtual)
helical gear and also using the standard developed for the
concurrent bevel gears strength calculus [2, 5].
By planar unfolding of the medium frontal cones of the
hypoid bevel wheels, two helical gear wheels result. Their
pitch helix angles βm1 and βm2 (fig. 1) are different. These
wheels are consisting a substitute non-parallel helical gear
(fig. 2, a), with the axes angle ϕP. Another substitute
parallel helical gear, made by intersecting the wheels with
a plane perpendicular to the pinion axis, corresponds to
METHODOLOGY AND SOFTWARE FOR the substitute non-parallel helical gear. As a result, the
HYPOID BEVEL GEAR DESIGN substitute helical gear (fig. 2, b) has a helix angle βm1.

Doru VELICU
Radu VELICU
Gheorghe MOLDOVEAN

Abstract: The design methodology, presented in this

paper, contains the relationships necessary for
dimensioning strength calculus of hypoid bevel gears
considering contact and bending stresses, the
relationships for geometrical calculus, considering the
manufacturing technology and also relationships and
recommendations for specific calculus factors. All these
calculus relations and recommendations are presented in
a table, on a logical sequence, ready to be used in the
design process. The software, designated for optimal
hypoid bevel gear design, is based on the previous
presented methodology and assures better efficiency of
the hypoid bevel gear design process.

Key words: hypoid bevel gear, design methodology,

software

1. INTRODUCTION

The hypoid bevel gears, mostly used at the main

transmission of motor vehicles, are non-concurrent gears.
Hypoid bevel gearings are spiral and are manufactured on
the same machines as the concurrent spiral bevel
gearings.
The research on concurrent bevel gears lead to the
development of an international standard ISO/DIN on
bevel gear strength calculus. In the case of hypoid bevel
gears there are less references and a gear strength
standard is not yet developed.
Even if the relative slippery between the tooth profiles is
relatively high, binding is not the main gear failure,
because the gears are made of cemented steels, with high
hardness, tooth profile has good finishing and good
quality lubrication.
As in the case of concurrent bevel gears, in the case of
hypoid bevel gears, the main stresses must be considered
the contact and the bending stress.
Fig. 1. Substitute non-parallel helical gear wheels
For the gear strength calculus, the gear wheels are
replaced with helical gear wheels with βm1 helix angle,
having the following properties:
• normal module of the substitute gear is equal with the
medium normal module of the hypoid gear;
• tooth height of the substitute gear is equal with the
medium tooth height of the hypoid gear;
• width of the gear is equal with the width of the hypoid
bevel wheel b2;
• tangential force at the pinion of the substitute gear is
equal with the tangential force at the medium section of
the hypoid bevel.
The contact stress checking, on the gearing pole, for the
substitute helical gear [1] is

251
 Ft u +1 • the overlap ratio usually being εvβ ≥ 1, the contact
σ HC = Z E Z H Z ε Z β K A K v K Hβ K Hα ≤ σ HP , (1) stress is calculated in the gearing pole [2, 6].
d1b u
By expressing the elements of the substitute (virtual) gear
where ZE is the elasticity factor; ZH – zone factor; Zε - (index vt), depending on the elements of the hypoid bevel
contact ratio factor for contact stress; Zβ – helix angle gear [2, 3], relation (3) becomes
factor for contact stress; d1 – pitch diameter of the pinion;
σ HC =
b – face width; KA – application factor; Kv – dynamic
factor; KHβ – face load factor for contact stress; KHα – 2Tt1 . (4)
= Z E Z H Z ε Zβ Z a K A K v K Hβ K Hα ≤ σ HP
transverse load factor for contact stress; σHP – permissible 0.85b2 d m2 2
contact stress.
Relation (4) gives the effective contact stress on the
hypoid bevel gear on which

cos β m1 ⎛ cos β m1 ⎞
Za = ⎜⎜ u cos δ1 + cos δ 2 cos 2 ϕ P ⎟⎟ (5)
cos β m 2 ⎝ cos β m 2 ⎠
is the geometric factor for contact stress of the hypoid
bevel gear.
Relation (5) shows that the Za factor is depending on the
geometry of the hypoid gear. The geometry is mainly
influenced by the centre distance a.
Checking relationships for bending stress, for pinion and
wheel, established for a helical gear [2, 3], applied on the
substitute (virtual) gear corresponding to the hypoid bevel
gear becomes
2T1uz 2 cos β m1
σ F 1, 2 = ⋅
beF d m2 2 cos β m 2 (6)
⋅ K A K v K Fβ K Fα YεYβYSa1, 2YFa1, 2 ≤ σ FP1,2 ,

where KFβ is the face load factor for bending stress; KFα –
transverse load factor for bending stress;
Yε – contact ratio factor for bending stress; Yβ – helix
angle factor for bending stress; YSa1,2 –stress correction
Fig. 2. Substitute gear (virtual) factor for bending stress; YFa1,2 – tooth form factor for
bending stress; σFP1,2 – permissible contact stress.
Depending on the pinion torque T1, relation (1) becomes After expressing the elements of the substitute (virtual)
helical gear depending on the elements of the hypoid
2T1 u +1 bevel gear, relation (6) becomes
σ HC = Z E Z H Z ε Z β K A K v K Hβ K Hα ≤ σ HP . (2)
bd12 u
T1uz 2 cos β m1
σ F 1, 2 = ⋅
For the substitute gear (see fig. 2, b), relation (2) becomes 1,7ψ Rm Rm3 2 sin δ 2 cos 2 β m 2
2
(7)
σ HC = ⋅ K A K v K Fβ K Fα YεYβYSa1, 2YFa1, 2 ≤ σ FP1, 2 .

2Tvt1 u vt + 1
= Z E Z H Zε Z β K A K v K Hβ K Hα
beH d vt2 1 u vt
In the case of the hypoid bevel gear, the pinion axis is
displaced toward the wheel axis in the direction of the
helix angle (see fig. 1). As a result, the medium helix
angle of the pinion βm1 is higher than the medium helix
angle of the wheel βm2, producing an increase of the
frontal module of the pinion and a stiffer construction.
From this reason, the gear strength calculus of the hypoid
bevel gear is mainly oriented to the strength calculus of
the wheel.
In order to transpose relation (3) as a checking relation for
the contact strength of the hypoid gear, the following
must be considered:
• beH =0,85b2, where b2 is the width of the wheel [2, 6];
. (3) Most of the hypoid bevel gears from automotive central
≤ σ HP transmission are manufactured on Oerlikon – Spiromatic
machines.
3. DESIGN METHODOLOGY
Table 1 presents a methodology (stages, relationships and
recommendations) for design of hypoid bevel gears with
machined with Oerlikon – Spiromatic technology. The
design methodology has two main stages. The first stage
is a preliminary design stage on which calculus factors are
chosen based on recommendations from literature, and the
main geometrical parameters are established. At the
beginning of the second stage, considering the results
from the first stage and the cutting tools parameters, the
real values of geometrical parameters and calculus factors
are established and, finally, the checking or dimensioning
calculus is performed.

252
Table 1. Relationships and recommendations for hypoid bevel gear design
No. Parameter Relationships and recommendations
I. PRELIMINARY DESIGN
1. INPUTS: pinion speed n1, rpm; pinion torque T1, N.mm; imposed gear ratio uinp; running life Lh, h;
functioning conditions; reference rack parameters; centre distance coefficient: 2a d m 2 =0,32...0,46, for
automobile central transmission; 2a d m 2 =0.23...0,33, for heavy trucks central transmission.
2. Gear steels and limit contact σ H lim and bending σ F lim stresses, MPa
3. Preliminary calculus
3.1 Gear ratio u and number of teeth for u 2,4 3 4 5 6 10
pinion z1 z1 15 12 9 7 6 5
Angle of the pitch cone for wheel δ2 [7],
δ 2 = f (d m 2 2a , z1 z 2 )
3.2
grades
3.3 Axes angle for the virtual gear ϕ P , grades ϕ P = arctg(tg ϕ sin δ 2 ) , where ϕ = arcsin 2a d m 2
3.4 Angle of the pitch cone for pinion δ1 [1, 2],
grades
δ 1 = arc sin (cos δ 2 cos ϕ A ) , where ϕ A = arctg tg ϕ sin 2 δ 2( )
3.5 Medium pitch helix angle for pinion βm1,
βm1 ≤ 50o; usual βm1 = 50°
grades
3.6 Preliminary medium pitch helix angle for β = β − ϕ
m2 m1 P
wheel βm2, grades
3.7 Preliminary calculus factors for contact stress
β m1 + β m 2 cos β m1 1
ZE =189,8 MPa ; Z β = cos ; ZH = 2 ; Zε = , ε vtα = 0,9...1,2 ; Za – see
2 sin (2α n ) ε vtα
relation (5)
3.8 Nominal addendum modification z1 5…8 9 10 11 12 13 14
coefficients xc1,2 xc2 = -xc1 0,70 0,66 0,59 0,52 0,44 0,38 0,30
3.9 Preliminary calculus factors for bending stress

Yε = 0,25 +
0,75
( ) (
, ε vtαn = 2; Yβ = 0,75 ; YFa1, 2 = YFa z vtn1, 2 , xc 1, 2 ; YSa1, 2 = YSa z vtn1, 2 , xc 1, 2 ;
ε vtαn
)
z1 z2
z vtn1 = ; z vtn 2 =
cos δ1 cos β m1
3
cos δ 2 cos β m 2 cos 2 β m1 cos 2 ϕ P
3.10 Preliminary load correction factors
KA = 1,25...1,5, for automobiles; KA =1,5...2,0, for heavy trucks; K v =1,05…1,20; K Hβ = K Fβ =1,5;
K Hα = K Fα = 1,4
3.11 Permissible stresses σ HP and σ FP , MPa [2, 3]
3.12 Medium generator length for the pitch cone of wheel
3.12.1 Width coefficient for wheel ψRm ψ Rm = b2 Rm 2 ; recommendation ψ Rm = 0,25...0,3
3.12.2 Preliminary medium length of the generator
of pitch cone from wheel, Rm 2 H from Rm 2 H = 3
T1uK A K v K Hβ K Hα
(
Z E Z β Z H Zε Z K Z a 2 )
1,7ψ Rm sin δ 2σ HP
2 2

contact strength, respectively Rm 2 F , from

T1u z 2 cos β m1 Y Y
bending strength, mm Rm 2 F = 3 K A K v K Fβ K Fα Yε Yβ Fa Sa
1,7ψ Rm sin δ 2 cos β m 2
2 2
σ FP

YFa YSa ⎛Y Y Y Y ⎞
where = max⎜⎜ Fa1 Sa1 , Fa 2 Sa 2 ⎟⎟
σ FP ⎝ σ FP1 σ FP 2 ⎠
3.12.3 Preliminary medium length of the generator
Rm 2 = max(Rm 2 H , Rm 2 F )
of pitch cone from wheel Rm 2 , mm
3.13 Medium normal gear module mmn, mm 2 Rm 2 sin δ 2
mmn = cos β m 2
z2
3.14 Medium frontal gear module mmt2, mm
2 Rm 2 sin δ 2
mmt 2 =
z2

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Table 1. (continues)
No. Parameter Relationships and recommendations
II. GEAR DIMENSIONING
4. Geometrical parameters of the substitute (virtual) helical gear (index υt)
5. Elements of functioning and exploitation
Chosen: lubricant; machining accuracy; profile and root roughness
6. Factors for contact stress, for dimensioning
cos β vtb 4 − ε vtα ε vtβ
ZH = 2
sin (2α vtt )
; Zε =
3
( )
1 − ε vtβ +
ε vtα
, for εvtβ < 1,0; Z ε =
1
ε vtα
, for εvtβ ≥ 1,0

7. Factors for bending stress, for dimensioning

( ) ( )
YFa1, 2 = YFa z vtn1, 2 , xc 1, 2 ; YSa1, 2 = YSa z vtn1, 2 , xc 1, 2 ; Yε = 0,25 +
0,75
ε vtαn
; Yβ = 1 − 0,25 ε vtβ

8. Factors for load correction, for dimensioning

K v , K Hβ , K Fβ , K Hα , K Fα
9. Permissible stresses, for dimensioning, σ HP and σ FP , MPa
10. Medium generator length for the pitch cone of wheel, recalculated
Rm2H, Rm2F – see 3.12.2; Rm 2 rec = max(Rm 2 H , Rm 2 F )
11. Medium normal gear module mmn, mm 2 Rm 2 rec sin δ 2
mmn = cos β m 2
z2
12. Cutting tool parameters
12.1 Cutting tool head, in order to assure the medium normal gear module mmn, from the normalised cutting tools
12.2 Generator length of the medium pitch cone Chosen from cutting tool diagram a value Rm2 pr which assures
from wheel, R m2 pr , mm (still preliminary) intersection with coordinate z02 in the central part of diagram
(towards the lateral boundaries); z 02 = z 2 sin δ 2
12.3 Medium normal gear module mmt2, mm 2 Rm 2 pr sin δ 2
mmt 2 =
z2
12.4 Medium pitch helix angle for wheel βm2, mmn
grades β m 2 = arccos
mmt 2
12.5 Medium pitch helix angle for pinion βm1,
β m1 = β m 2 + ϕ P
grades
12.6 Generator length of the medium pitch cone mmt1 z1
Rm1 pr = ; mmt1 = mmn cos β m1
from pinion, Rm1 pr, mm 2 sin δ 1
12.7 Checking of the gearing condition
Rm1 pr cos β m1 sin δ1
1− u ≤ 0,03 .
Rm 2 pr cos β m 2 sin δ 2
If this condition is verified, final medium generator length of the pitch cone from wheel Rm2 = Rm2 pr and
geometrical gear calculus is performed; if the condition is nor verified, calculus is restarted from 10.2.

4. SOFTWARE

Geometry and strength (dimensioning and checking) gear

calculus are stages of gear transmission design on which a
computer program is absolutely necessary. Following
several calculus methodologies depending on series of
optimization criteria, high volume of input data, design
steps and output data, calculus complexity recommend
development of specific software.
Based on the previous theoretical elements, a software for
hypoid bevel gear design has been developed using
Windows object library.
Figure 3 shows the main menu of the software, with the
following main stages: Input Data, Dimensioning,
Output Data and Exit. Fig. 3. Main menu

254
The software is presented, as follows, based on the frames
used for solving a concrete application of design for a
hypoid bevel gear from the central transmission of a
heavy truck.
Input data are divided on three categories as follows:
¾ Technical Data (fig. 4) gives the possibility of
introducing data concerning: transmitted load, imposed
durability, functioning conditions, constructive solution.
In the case of some of these elements, there is the
possibility to chose between two variants: transmitted
power or torque at the pinion (both depending on the
rotational speed of the pinion); running life time or
number of loading cycles (also depending, both, on the Fig. 5. Functioning conditions
rotational speed of the pinion).
In the case of certain input data, there are
recommendations to be followed or buttons sending to
other frames with specific information. By clicking on the
button Chose the Application Factor, the frame presented
on fig. 5 opens. Type of engine and load variation are
selected from a list, and automatically the value of the
application factor KA results. By clicking the button
Chose the Centre Distance Coefficient the frame
presented in fig. 6 opens. After selecting the transmission
type, recommended values for the centre distance
coefficient are presented and the value of the coefficient
2a/dm2 can be set. Supplementary input data for gear
strength calculus are introduced in the frame presented in
fig. 7.
Fig. 6. Centre distance coefficient

Fig. 7. Supplementary input data

¾ Parameters of the Reference Rack (fig. 8) allows

Fig. 4. Technical inputs
setting of the parameters of the reference rack.
¾ Constructive Solution (fig. 9) gives the possibility of
choosing between the three constructive position of
pinion and wheel towards bearings. Thes input data are
necessary in order to establish the face load factor for
contact stress KHβ and for bending stress KFβ.
Dimensioning stage develops in the following steps:
¾ Material Selection (fig. 10). Gear steel can be chosen
between four groups of steels and thermal or thermo-

255
chemical treatments. By selecting a group of steels, stage. In this phase, the geometrical parameters of the
recommended values for limit contact and bending cutting tools head are also introduced.
stresses and also usual hardness are highlighted. Values of
the limit contact and bending stresses are separately
introduced for pinion and wheel.

Fig. 9. Constructive solution

Fig. 8. Parameters of the Reference Rack

¾ Preliminary Calculus contains: establish of the

preliminary calculus factors; calculus of the preliminary
permissible stresses and preliminary calculation of the
generator length of the medium pitch cone of wheel.
There are also set values of the radial and tangential
profile modifications, based on recommendations (fig.
11).
¾ Chose of the Cutting Tools Head (fig. 12) is based on
specific machine tools diagrams, depending on several Fig. 11. Addendumm modification coefficient
parameters determined during the preliminary design

Fig. 10. Materials, treatments and limit stresses

256
 stages are performed. In the case of special situations
from the design process (not checking of the gearing
condition, need for another material, too large dimensions
etc.) the software is giving recommendations or
solutions.

Fig. 12. Cutting tools head

¾ Dimensioning Calculus is consisted of calculation of

the geometrical elements of the substitute gear, calculus
factors for dimensioning, permissible stresses for
dimensioning. The generator length of the medium pitch
cone of wheel is calculated again depending on strength Fig. 13. Calculus factors
conditions. Due to differences toward the preliminary
calculus, there may appear the necessity of changing the
previous chosen cutting tool head going back to the
previous step.
¾ Geometrical Calculus can be performed after
establishing the final parameters of the cutting tools head,
which are directly influencing the geometry of the hypoid
bevel gear. Geometrical elements are determined with
high precision. Finally, gearing condition must be verified
(both pinion and wheel must have the same module).
Output Data resulting from strength and geometrical
calculus are presented in different frames:
¾ Calculus Factors (fig. 13), are presented depending
on the stress or on the wheel they are used for.
¾ Stresses and Materials (fig. 14). At the end of the
strength calculus, the width coefficient (determining
width of pinion and wheel) is re-calculated for an optimal
dimensioning of the hypoid bevel gear. There are also
shown the effective contact and bending stresses along
with the permissible stresses.
¾ Geometrical elements (fig. 15) are presented divided
in three sections referring to the whole hypoid gear,
pinion or wheel.
Calculus can be performed any time needed, in order to
get to the optimal solution. The software is developed so
that the user must follow the logic of the calculus process.
Some of the stages are not active until some compulsory Fig. 14. Stresses and materials

257
 Fig. 15. Geometrical elements

REFERENCES CORRESPONDENCE

[1] NIEMANN, G. Maschinenelemente, Band 2, Berlin Doru VELICU, Prof. Ph.D. Eng.
Springer Verlag, 1975 Transilvania University of Braşov
[2] VELICU, D., MOLDOVEAN, GH., VELICU, R. Faculty of Technological Engineering
Proiectarea angrenajelor conice şi hipoide, Editura Eroilor Str. 29
Universităţii Transilvania din Braşov, 2004 500036 Braşov, Romania
dvelicu@unitbv.ro
[3] MOLDOVEAN, GH., VELICU, D., VELICU, R.,
Angrenaje cilindrice şi conice. Calcul şi construcţie,
Braşov Editura Lux Libris, 2001 Radu VELICU, Prof. Ph.D. Eng.
Transilvania University of Braşov
[4] VELICU, D., JULA, A., MOGAN, GH. (1997) Faculty of Technological Engineering
Aspects concerning the Hypoid Gear Calculus. Eroilor Str. 29
Proceedings III Konferencja Naukowo–Techniczna 500036 Brasov, Romania
Wspolczesne Metody Konstrukcji I Technologii rvelicu@unitbv.ro
Elementow Uzebionych, Lodz, pp. 167-173.
[5] DIN 3991. Trägfähigkeitsberechnung von Gheorghe MOLDOVEAN, Prof. Ph.D. Eng.
Kegelrädern ohne Achsversetzung Transilvania University of Braşov
Faculty of Technological Engineering
[6] DIN 3990. Tragfähigkeitsberechnung von Stirnrädern Eroilor Str. 29
[7] Oerlikon–Spiromatic. Berechnung, Werkzeug- 500036 Braşov, Romania
maschinenfabrik Oerlikon – Bührle AG ghmoldovean@unitbv.ro

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