Bl~CIi TO BASICS ...

-------------

Helical Gear Mathematics

Formulas and Examples
Earle Buc:kin,gham
fliot K. Buckingham
Buckingham Associates,. Inc.
S~eld,
VT

AUTHOR:

The foUowing excerpt is from the Revised Manual of Gear

Design, Section 1Il, covering helical and spiral gears. This seetion on helical gear mathematics shows the detailed solutions
to many general helical gearing problems. In 'each case, a.
definite example has been worked' out to illustrate the solution.
Al!lequations are arranged in their most effec:ti ve form for use
on a computer or calculating machine.

ElIOT K. BUCKINGHAM is presidmJ of Budringhmn' Associales.

Inc .. a consulting finn worbng in the ar"lla5,of des(g7I, application and
manufacture of gears for any type of drive. Mr. Buckingham eamed his
B. S. from Massiuhusetts Institute of Technology and his M.S. from the
Univ.ersity of New Mexico. He is the /luthor ofT ables tOT RalessAction
Gears tlnQ t1Umerous technical papers, as well as the revised edition ,of
The Manuall of Gear Design by flute Buckingham. He is " member of
ASME QJ1da Registered Professional.&lgineer in the State of Vemr.ont.

'Given tha pitch radius and lead of a helical gear, to determine the helix al'lgle:
When.

R '" Pitch Radius of Gear

!l - !lead ot Tooth
"" == Helix Angle

Then,

Exampl'e:

2 ... FI
TA_N!It .. -IlPI ",,3.000

l - 2U)OO

2 x 3.1416 X 3.0001
TAN"" ""
21.000
'" .89760
The iinvolute ,of a cir'cle ls the curve that is described by 1he end of a line which is unwound from
the circumference ota circ~'eaS shown in ,Fig'. 1.
When,

Fib

I(} '"

Base Radius
Vectorial Angle
Length of Ra.dius Vector

8 ..

'Given the arc tooth thickness and pressure angle in the plane of rotation of ahslieal gear at a given
radius, 10' determine its tooth thickness at any other radius:
rl - Given Radius

When,

tPt

Pressure Angle at rl

T1,

ARC Tooth Thickness, at rl

r2 - Radius Where Tooth, Tflickness Is To Be Determined:

1/12 "" Pressure Angle' at r2
T2

""

TIlen,

ARC Tooth, Thickness at

rl COS

'2

!PI

COS tP.2 ..

I!xample:

r2 '" 2.600
!/l1 '" '4.500"

C~

1/12 '"

Cos 411 '" .9Sa1S

..00554

,2.500' x .96815
2.600
:; .9309,11

---f-.-

IINV 1/12 '" .01,845

.2618 +.
.'. 005"''''
- 2'051
T - 2 x. 2.600 I~.
. ..... - '.0,11845')
..'
-.
"
2
..
_. . . ( 5.000

Fig. 2

Given the herix angle, normal diameUal pitch and numbers of teeth, to determine the center distance:
When"

I/!

IHelix Angle

Nil

Number of Teeth in Pinion

N2 .. Number of Teeth in Gear

C...
Pn

""

Center Distancs'
Normal Diametral Pitch

Then,

C ..

1'\11

+ N2

2 Pn COS I/!

lEx.ample:

I/!

30

24 +48
C '" 2 x 8 x .86603

36 'Gear Technology

Nl '" 24

.. 5.1'9611

COS I/! ... 86603

--- . ---

Gl,ven the arc tooth thickness in the plane of rotation at a given radius, to find the n.ormal chordal
thickness and the nonnal chordal addendum:
When,

T ,." ARC Tooth Thickness at R in Plane of Rotation

Tn "" Normall Chordal Thickness at IR

a'n '..

Normall Chordal Addendum

IRo

Outside' Radius

roo

R '''' IP,itch Radius

!/t - !Helix Angle at R

Then,

T COS2 'f
ARC B '"

2R

Tn .. 2 R SIN B
COS '"

0'11 ""
Example:

Ro -

COS B

T . 2267

!/t-

30"

Ro

11.8570

R "", 1.7320

COS '" - .86603

COs

'" ::

.75000

.2267 x .7500
ARC B '"

== .'04908

2.x 1.7320

SIN B ... 04906

COS B

.99880

2' x. 1.7320 )( .04906

Tn -

'" .1962

.86600

Fig. 3
'Q\, -

1.8570 - (1.732,0)( .99880) .. .1271

Given the ,circular pilCh and pressure al1lgle in the pl'ane of rotation and the helix angle of a helicall gear, to, detennine the
circular IpilCh and the normal pressure 8n9[9':
When.

normal

!/t ., Helix Angle

.1/> -

P,ressure Angle in Pl'ane ,of Rotaliion

IP .. Circular P,itch in Plane of Rotalion

I/ln

..

Pn -

Normal Pressure, Angle

Normal Circular Pitch

Then,
II' .. P COS '"
Example:

II!

.3927

TAN 'I/ln= TAN tP COS '"

COS", ... 92050

'" = 23"

Pn "" .3927 x .92,050 ... 361148

TAN

<Pn ""

.36397

TAN <p

II

36397

.92050 "" .33503

I/>n - 18.522

Mayl.k.Lne 19,8837

Given the arc tooth thickness and pressure angle in the plane of rotation at a given radius, to determine the radius where the tooth becomes pointed:
Wh.9n,

rl: -

Given Fladius

r2 -

Radius where Tooth iBecomes P,oirlted

Tt

""

ARC Tooth Thickness at

!/it "'" Pressure, Angle at

Ir1

t:P2 "" Pressure Angle at

r2

TIl

Then,

rl COS 1/11

r-""
2

Example:

r1

COS

4>,2

;2.500

Tt

411 - 14.500

.2618

INV tPl .. .00554

.2618
INV t:P2 .. 2 x .2.500

IP2 .. 30.693

Fig. 4

+ .00554 ... 05790 Radians

COS tP2

<=

COS

.85991

411 ... 96815,

2.500 x .968115
.B5991

"" 2.8147

Given the normal circular pitch, the normal pressure angle and the helix angle 01 a he'licalgear, to determine the circul'ar pitch
and the pressure angle in the plane ot retanen:
1/1 ""

Helix Angle

n ==

Normal Pressure Angl'e

PM

Normal 'Circular IPHoh

tP, .. Pressure Angle in PI'a_neo~Rotation

P .. Circular Pitch in ,P,lane of BOlation
Then,

prJ
p ... cos

1/1

TAN n
TAN I/l' .. COS 1/1
COS

Example:
.5236
P ,= .90631 ... 57772

38

'Gear Technology

..J.o

..

.90631

TAN

.3639'7
TAN I/l ". 90631 ... 40159

In ..

.36397

t/i .. 21.8800

Pn ... 5236

Given the tooth proportions, Ilnlhe plane 'of rotaliion of a pair of !helical gears (par.al1el shafts), to determ]ne,lhe, center distance ,aJ whIch Ihey wUl mesh l'i9'htly:
f11

Given Radi'us of 151 'Gear

f2

Given Radius of 2ndl Gear

N1

Number of Teelh In 115t Gear

N2: :

Number of Teeth lin 2nd Gear

411 .. Pressure Angle at r, and

412' -

If2

Pressure .Angle aJ Meshing Position

T1 .... ARC TOOlh Thickness al f,

T2 - ARC l'OOIhTihlclmess
01

..

al

~2

Center Distance for Pressu~e Angle

4>,

C2 .. 'Center Distance for Pressur,e Angle 412

Then.
Nl (Tl + T 2l -2wrl
IINV

4>2 -

2'

fl

ell cos
C:!...
EXample:

Irl ".,

411

COStb2

:2.500

Ag.5
Nl ...

Tl ~ .2800

r2 '''' 4 ..000.

INV!/>2 -

+ INV 411

(Nl + N.2l

T2

3()

C,=

.2750

30 (.2800 + .2750) - 2r x 2~SOO

2 x 2.500 (30 + 48)
+ ..,00545=

oos

9.500

..007955

2 ,. .95973

6.500 x .968,15

C2 -

.95973

- 6.5570

Given the IPitch, radius and heli.x angle of a helical 'gear, to determine
When,

the lead ,o1ttls, tooth.

PHch Radius

L "'~ Lead ,of Tooth

1/1 -

Then,

!Example:

llielix Angle

2T:R
L ,. TAN

TAN t/I '" .41421'

R - 2.5001
2 )(3.1'416)(
L -

.41'421

2.500
... 37.9228

May/JllJne 1988, 39

Gillen the number of teeth, ,helix8ngle and proportions of the normal basic rack of a. helical gear,
, to determine the pitch radius and the !base radius:
When,

N = Number of Teeth

t/t = Helix Angle at R

Pn

Normal :Dlametral Pitch

'
P,itch Radius

R-

q,r!

Normal Pressure Angle

q,. - Pressure Angle in Plane' of Rotation

Rb ::: Base Radius
Then,
R =2

Fib
Example:

TAN cPr!

TAN cP

Pn COS '"

""COS t/t

N COS cP
FI COS cP =2 Pn COS t/t
COS y,. '" .90631

30

TAN cPn '" .25862

30
R == 2

x 6 x .90631

=_.,'27584.

.25862

q, '"

TAN

.90631

Rb " - 2

cos cP

.28535,

30 x .96162
...
x 6 x .90631

'"

.96162

= 2,65256

Gillen the normaJ diametraJ pitch, numbers of teeth and center distance, to determine, the, lead and helix angle:
When,

Number of Teeth in IPinion

N2 "" Number of Teeth In Gear
Pn

Normal :Diamatral Pitch

=
t/t =
Lli =
L2 =

Center :Distance

Then,

"'=

COS

Helix Angle
Lead of P,in,ion
Lead of Gear
Nl

+ N2

~ N2
l2 '" Pn SIN I/;

2Pn C

Example:

C
18
COS",

=
=

40 Gear Technology

4.,500

+ 30

2 x 6 x 4.500 - .88889
3,1416 x 18

Ll

6 x ..45812

== 20.5728

SIN y,. '" .45812

3.1416 x 30
L2 "" 6 x .45812 "" 34.2880

Given the tooth pro,port.ions in the Iplane of rotation of a hetica:i gear, to determine the' position ofa
mating rack of ,different ,ciroular pitch and pressure angle:
When.

"'1"

Given He'llx Angle at Rl

'1/12 ..

Helix Angle for Mating Rack

iii ,.

l/tr, .. !Base IHelix .Angle

nl

.,

1-

Rb

T,

INa mallPressure

!Base, RadiLls
Addendum

of IFlack

AAC Too~h TI'llckness at A,

N .. INumber of Teeth

Angle at R,

.x ..

n2 .. IPressure Angle of Mating Rack

, .. Pf\8SSure Angle at lA, in Plane of Flotation

Pnl

2 ., Pressure Angle ot lMaJing Rack in P,lane of Rotation

Pn2"

..

Distane,e from Center of Gear to Tip of Rack Tooth

Normal Circular Pitch at A,
Normall Circular Pitch of IFiack

IAl '. Given IPitch Radius

Must IBe IEqual To (PI12COS 1121'

Note: (Pnl COSnl

IR2 - IPitch Radius with Mating Rack

SIN

ifb ., SINII/I, 'COS

nl

"'b

SINI
SIN !It, COS l'I1
SIN, 1/12 .. ' 'COS n2 ..
'COS n2
TAN n2
TAN 2 .. COS ..1.
'1':2.

Fig .. s
Example:

"'1

,n2 ... 20
SIN

!ltl

oz.

.42262

'COS

COS

"'1 ...

SIN Vt.2 ,..,

TANtbn1

.90631
COS

.50692] .. [Pn2 COS

IPnl ..

A,b .. ,2.65258

T, -.2888

a - .185

Po, .., .5236

IIPn1

R, .. 2.7584

, .. 15.926

,25

..42262 x .96815
.9,3969
- .43542

IPnl ""

IPn2 '"

25862

...

COSIPn2 .... 93969

.96815

.50692:)

!It2 .. 25.812

00SI/I2

... 90023

.3639'7
TAN 2 ... -.-. --, . - .40431

IP2 - 22.014

.90023,

INiV

R2"

4>2 "" .020093

2.65256,
c
..92709
--c

'"'

INV

tb1

COS tP2, ...

92709'

.007387

2.86117

,X '" 2.86,117 _ .185 +

.. 1

.' [5,.72234( ... 2_888_ + .007387 _ .020093).

,2 )( .404311,

. 5.51168

_ .31416 ~~.86117]1

2.5729

Given the center distance, number of teeth, and basic rack proportions (.hob proportions) of a pair
of helicall gears, to determine the hobbing data:
When.

<fine ,= Pressur,e Angle of Ho'b

N.2

Number of Teeth in Gear

=
ac =

Diametral Pitch of Hob

Ro2

Addendum of Hob

Rr2 - Root Radius of Gear

C1

Center DiS1.ancewith Pressure Angle of <fIl

l2 '" Lead of Gear

Given Center Distance of Operat,ion

R2 - Pitch Radius ,of Gear

Pnc

C2

Nl == Number of Teeth in Pinion

Outside Radius of Gear

b2

Oed'endurn of Gear

OIJ~side Radius of Pinion

1/12'

Helix Angle' of Operation

Root Radius of Pinion

rPl

Pressure Angl'e of Generation in Plane of Rotation

Lead of Pinion

<fI2

Pressure Angl'e of Operation in Plane of IRotation

Rll == P,itch Radius 'of Pinion

P1

Diametral IPitch of Generation In ,P,laneof Rotation

b1 == Oedel'ldl.lm of Pinion

hI

Total Tooth Depth of Gears

ROl

Rrli
ILl

1/11 == J-Ie'lixAngle of Generation

Then,

Ma:ke trial calculation for lead as follows:

COS

""1 ..

Nl "'" N2
2 Pnc C2

Select values for Ll and: L2 which can be readily obtained on the hobbing machine:
Then.
TAN rP1

TAN rPnc
COS 1/11
C1 COS <fIl
COS <fI2=

:1'1 - Pne COS 'fll

1:11 ..

INote: When smallest N is 30 or more, then,

R2=

Nl + N2
,.'932

102

2 7r R12
TAN 1/12 '" -=
L1

42

Gear lechnolog;v

b2=

C2 - (Rr1 "'" Rr21

2

N2 'C2

Nl O2

ht

b1

(Rn "'" Rr2l

11"

-----

Nt "'" N2

IR2

IL2

(Continued On next page)

Exam.pfe:

Pnc

tbnc ... 14.500

Ac =

.2314

TAN tbnc .. .25862

Triall Calculation:
20 + 60
COS "', - 2 x 5 )(9.00 .. .88889

SIN '" -

.45812

60r
Illl ...

5, x .45812 ". 2'7.4303

_",:0 2-' .. ,82.2909

5 x.. """",,1
.

We, willi select the following values for Il, and L2:

Il, ... 27.500

20.".
SIN",

... 5

27.500 :: .45696

,25862
TAN 411 - ,88969

IINV 41, ....

COS 411 ... ,96025

,29069'

oonse,

20 + 160
,
C "" 2' x 4.44745 - 8.'99392

p, - 5, x .88949 .. 4.44145

8,,'991392 )( .96025
COS

th ..

INV 4>2 -

.95960

.007994

,8.99392

.(Rft

A,v

::: B.99392 - 2

x .2314 +

9.00 -8,5372
b, ..

1 ... ~

"" .169GB

.29069 fOO7994 -

.0077961 =8.5372

9'.00 -8.5372'
b2 "'" 1 +

fo6O ...29340

20.x '9,00

R, R,r1

'"'

--

--

201"" 60

= 2'.250

2.250 - .16938

2,08062'

hi ., .932 [9.00 - 8.5372]

Flo, ..

2'.oaos.2 "" .43133 - 2.51195

.,

21.5

The specifications

- ,.29340 .. 6.45660

Ae:2 ...

... ,.431133

... .43133

2 r2.25O
TANlif2

1=11'2 "" 6.750

.... 514019

"'2 ..

6.45660

6.88793

for this pair of gears are as ronows:

1=1,1 ... 2.08062

L2

Flo, ..

N.2 - 60

R'r:2 .. '6.45660

A, .. 2.250
Il, ,..,27.500

'

27.207

IN, ,.., 20
2.51195

Ao2 ... 6.88793

R2 .. '6.750

82.500

Helix angle for hobbing

.. 27.1910

.. 9',00

May/June 1988

Given the prcperticnaot

When"

Rl
R1)1 '"

an internal helical gear drive, to determine the contact ratio:

Pitch Radius oI Henes.1Gear

FI.2 - Pitch IRadius of Internal Gear

Outside Radius of Helical Gear

Ri == Internal Radius of Internal Gea'r

RbI :: Base Ra.dius of Helical 'Gear

Rb2

Base Fladius of Internal GeeJ

tP :: Pressure Angle in Pl'ane ,of Rotation

p - Circular Pitch in IP,laneof' Rotation
C -Center

IDistanoe

mp ,., Contact Ratio

Then,

..JR012

Ab12

mp ::

:Example:

+ C SIN.cP - ..JFI? p COS tP

Rl "'" 1.250

,R01

R2",3.500

IAJ,== 3.4375

SIN tP -

'"

11.4375

COS tP,

.34202

..j(1.4375)2

- (1.1746)2+

mp""

Glvenlhe
When.

,= 3.2888

cP'"
C

200

p "" .3927

2.250

.93969'

(2.250 x .3420.2) - ..j(3.4375)2

.3927

preponlens
F

Abl '" 1.11746

Rb2

Flb2

.93.969'

- (3.2888)2

1.'62

of a. pair of helical gears, (external! or internal). to determine the face contact ratio:
Face Width

p .. Circular Pitch In PI!aneof Rotation

y, ..

Henx Angle

m, '" Face Contact Ratio

Then,

F TAN

m,oo

Exarnp'le:

F = 1.50.0.
l' .500

m, =
I

.3927

.300

TAN y,' == .57735

.57735

'" 2.20.

.3927

mp '"" Contact Batlo,

mt = Face Contact Ratio

m,
I

y, =

Given tile proportions of a pa.irof helical gears (external ,or internal)., to determine tile total contact ratio:
When.

!
,

y,

==

Total Contact Ratio

Then ..

Example:

mp

= 1.59

ml = 11.59

44

Gear Technology

ml' '"

*' 2.20

.2.20

;: 3 ..79'

TOOTH

ROOT 'S~RESSES,..

(continued !rom page 20)

estimated), the amount of crowning should be chosen in such
a w.ay 'that when applying the service load, the lowest root
stresses will be the result. This criterion is satisfied when the
product

reaches a minimum.
As an example this optimization is performed for the test
gears in Fig. 18. One can see that the curve for ICc has a fIat
minimum in the area of small crowning values (near gear set
B). This result seems to, be plausible because of the very stiff
test rig.
It should be noted that the optimization method introduced
here is only based on the tooth root. stresses and should only
be used if tooth breakage is the c:ritka~ failure criterion. An
optimization for contact stresses may be quite different and
usually provides a guide to higher amounts of crowning.

Summazy
By strain gauge measurements

,of spir.al bevel gears, the

influence of lengthwise crowning and relative displac1!ments
between pinion and gear on tooth root stresses was investigated. It was found that the crowning effects the load
distribution over the lines of 'contact and the load sharing
between pairs of teeth meshingsimul,t.aneously,
For both influenc:,es.a. quantitative description. could be derived.

(continued on page

47)

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..~~oo

50

1',

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..

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pinion

ZOO
150

p1nlon C

Fig. 16 -Influence of combined displacements on the maximum root stresses at mu at the pinions. (Amounl of crowning, see Fig. 2.)

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GEAR TECHNOLOGY. The JournaJ of Gear Manufacturing.

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TOOTH ROOT STRESSES ...

(continued from page 45)

1,3

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1

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gear set

c~/b.l000

F.[g. HI- Optimization of lengthwise

In the case of relative displacements, deviations in pinion

mounting distance and in offset have the strongest influence
on the root stresses. A method was introduced to determine
the increase or decrease of maximum stresses that have to
be expected tor a combination of certain values of these
parameters ..Further, a optimization criterion was derived that
allows finding the amount of lengthwise crowning producing the lowest root stresses for a certain service condition.

References
1. WINTER,. H., PAUl, M. "Influence of Relative Displacements
Between Pinion and Gear on Tooth Root Stresses of Spiral Bevel
Gears." Gear Technology, July/August,
1985.
2. JARAMILl:O,

T.J. "Deflections

and Moments

due toa

Con-

crowning.

Load on a Cantilever Plate of Infinite length." Journal of Applied Mechanics, VoL ]7, Trans., ASME, Vol. 72 1950,
S. 67-72, 342-343.
3.WELLAUER, E.J., SEIREG, A. "Bending Strength of Gear Teeth
by Cantilever Plate Theory." Journal of Engineering for Industry. Trans. AS ME,. Aug, 1960, S ...213-222.
4. AGMA.2003 - A86: Standard tor Rating ,the Pitting Resistanoe
and Bending Strength of Cenerated Straight Bevel, Zerol Bevel
and Spiral Bevel Gear Teeth, 1986.
S. DIN 3991: Tragfahigkeitsberechnung
von Kegelradem oboe
Achsversetzung: Normentwurf, 1986.
6, COLEJ:vlAN, W. "Improved Method for Estimating Faligue Life
of Bevel and Hypoid Gears." SAE Quarterly Transactions, Vol.
6, No.2, 1952.centrated

'7, COLEMAN,

W. "Effect of Mounting Displacements 001'1 Bevel

and Hypoid Gear Tooth Strength." SAE-Paper 75 01 51. 1975.

May/June 1988 47