231

CONSIDERATIONS ON THE
GEOMETRICAL ELEMENTS
CALCULATED FOR CIRCULAR ARC
TEETH BEVEL GEARS, 528 SARATOV
TYPE

Niculae GRIGORE
Adrian CREITARU


Abstract: The work presents theoretical and
technological considerations regarding the circular arc
bevel gear type 528 SARATOV, technological principles
developed for machining of this type of teeth, manner of
choosing it and construction of tooth by means of cutting
tools used with this method.
The work approaches the algorithm of calculation for
geometric elements of the teeth and specific parameters of
construction and control for cutter holders used in the
tooth construction of such gears.

Key words: bevel gear, circular arc teeth, Saratov gear
cutting machine, gear geometric elements


1. GENERAL CONSIDERATIONS

The circular arc teeth bevel gears are used for 3...40 m/s
speed range conditions [2], [7].
At higher speed conditions, the teeth shall be ground after
thermal treatment and curved tooth bevel gears have got
the following advantages:
silent operation;
large contact ratio;
long lasting in operation;
allowing for high gearing (velocity) ratios;
low overall etc.
The principle at the basis of the curved teeth bevel gear
machining consists in generating, by an imaginary crown
(plain) wheel pattern, a tooth construction tool to get each
single tooth of such face gear (Fig.1) [1], [7], [9].
The cutting tool for the tooth construction of such type of
bevel gears is a milling cutter head on which external
cutters are fastened that cut the external side of the cutter
head while inner cutting tools cut the internal side of the
cutting tool head.
The cutter head carries out the main rotation motion with
at the same time generating the tooth of the plain wheel.

Fig. 1. Crown (plain) generating wheel pattern

2. TECHNOLOGICAL ASPECTS

In order to achieve the profile of the bevel gear there also
must be, during tooth construction, a rolling motion
between the gear and the generating plain wheel [3], [7].
The shape of a cutter head (holder) and details over cutter
holders are shown in figure 2.


Fig. 2. Cutter head (holder) assembly
232
Nominal diameters of the main cutter holder heads are
shown in table 1.

Table 1. Nominal Diameters of Cutter Holder Heads

D
s
[in]
3
1
/
2
6 9 12 18
D
s
[mm]
88.9 152.4 228.6 304.8 457.2

Selection of a certain size of the cutter head will be done
depending on the gear modulus, m
t
and the length of its cone
distance (R, element of the cone) [7], [10].
To choose the typo-dimension of the tooth construction
head, such nomographic chart are used as the type of that
shown in figure 3.
Typically, in order to machine bevel gears with curved
teeth and constant height, the unilateral method is used
consisting in the fact that in machine tooth finishing on
both gears (rack and pinion) cutting of concave and
convex parts is separately achieved.
To roughen the two components of the gear, a same head
of gear cutter head is bilaterally used.
Convex parts of the pinion teeth are achieved by means of
inner cutters while concave parts are achieved by means
of external cutters of the cutter holder head.
After teeth has been rough-machined, the finishing job is
carried out for convex sides by changing coordinates on
the cutter holder head and then finishing of concaves
sides, by properly changing again the head coordinates.


Fig. 3. Nomographic chart used for Selection of the Size
of the Cutter Head proper to the Bevel Gear Tooth

This method of machining curved bevel teeth is used in
case of small scale production. This way, a favourable
area is assured in contact gearing between conjugated
sides of the gears.
3. CALCULATION OF GEOMETRICAL
ELEMENTS OF 528 SARATOV CIRCULAR
ARC TEETH CONSTANT HEIGHT BEVEL
GEARS

Further on, in figure 4, you have the computing algorithm
for the gear geometric elements [7].
Fig. 4. Basic rack tooth profile and the constant height
circular arc teeth bevel gear assembly

3.1. Basic data

The teeth numbers of the gears are done by the topic:
on the pinion: z
1
;
on the gear: z
2
.
Outside module (frontal) is:

m

Gear ratio, u:

1
2
z
z
u = (1)

Medium inclination pitch angle:

m


Pressure pitch (normal) angle:

0
20 =
n
(2)

Reference tooth addendum coeficient,
*
a
h :

0 . 1
*
=
a
h (3)

Reference dedendum clearance coeficient,
*
c :
233
25 . 0
*
= c (4)

Face width coeficient:

4 ... 3
1
= = =
b
R
k
R
b

(5)


Radial profile displacement coeficients:
on the pinion:

=
2
1
1 cos 49 . 0
1
u
x
r
(6)

- on the gear:

1 2
r r
x x = (7)

Tangential profile displacement coeficients:
on the pinion, it must be chosen related to gear ratio:

Table 2. Recomandations for tangential profile
displacement coeficients choice

u 1...2 2...2.5 2.5...3 >3
1
t
x
0 0.16 0.17 0.18

on the gear:

1 2
t t
x x = (8)

3.2. Calculation of the bevel gears geometrical
elements

Pitch angle:
on the pinion:

=
u
1
arctg
1
(9)

on the gear:

( ) u arctg
2
= (10)

Pitch diameters:
on the pinion:

1 1
z m d = (11)

on the gear:

2 2
z m d = (12)

Outer cone distance:

2
2
1
1
sin 2 sin 2
d d
R = = (13)

Face width:
R
k
R
b
R
b
= = (14)

Mean cone distance:
2
b
R R
m
= (15)

Inner cone distance:
b R R
i
= (16)
Module (interior):

b
b
i
k
k
m m
1
= (17)

The addendum:
on the pinion:

( )
i r a a
m x h h + =
1 1
*
, cu
2 1
r r
x x = (18)

on the gear:

( )
i r a a
m x h h + =
2 2
*
, cu
1 2
r r
x x = (19)

The dedendum:
on the pinion:

( )
i r a f
m x c h h + =
1 1
* *
, cu
2 1
r r
x x = (20)

on the gear:

( )
i r a f
m x c h h + =
2 2
* *
, cu
1 2
r r
x x = (21)

The whole depth of teeth:

( )
i a
m c h h + =
* *
2 , unde h h h = =
2 1
(22)

Outside (addendum) diameters:
on the pinion:

1 1
cos 2
1 1

a a
h d d + = (23)

on the gear:

2 2
cos 2
2 2

a a
h d d + = (24)

Root (dedendum) diameters:
on the pinion:

1 1
cos 2
1 1

f f
h d d = (25)

on the gear:

2 2
cos 2
2 2

f f
h d d = (26)

Addendum cone angle:
on the pinion:

0
1
=
a
(27)

on the gear:

0
2
=
a
(28)

Dedendum cone angle:
on the pinion:

0
1
=
f
(29)

on the gear:

0
2
=
f
(30)

Outer addendum angle:
on the pinion:
1
1
=
a
(31)

on the gear:
2
2
=
a
(32)
234
Inner dedendum angle:
on the pinion:

1
1
=
f
(33)

on the gear:

2
2
=
f
(34)

Distances from the apex of the pitch cone to the back of
the hub:
on the pinion:

1 1
sin cos
1 1
=
a a
h R H (35)

on the gear:

2 2 2
sin cos
2
=
a a
h R H (36)

Mounting distances:
1
L and
2
L shall be chosen by constructive necesities.

Addendum distances:
on the pinion:

1 1
1 a a
H L L = (37)

on the gear:

2 2
2 a a
H L L = (38)

The nominal diameter of the cutter holder,
s
D , shall be
chosen out of figure 3, depending on R and m.
The arc bevel teeth angle of splitting slope is variable
along the flanks of gear (fig. 5). Therefore in order to
define the indexing slope external angle, the outside of the
tooth arc is considered a radial direction tangent to such
arc (point A), while for the indexing slope internal angle
inside the arc, a radial line tangent into point B. Similarly,
the medium indexing slope angle can be defined into a
point located at half the width of the gear teeth (point M).


Fig. 5. Definition of external (
e
), internal (
i
) and
medium (
m
) indexing slope angles

The external indexing slope angle,
e
, may be determined
with the relation:

s b
b
b
b
e
D
R
k
k
k
k

=
2
2
1 2
1 sin
2
1 2
sin (39)
The graphical method [4], [5], [6], [7] allows for quick
determination of such angle by making use of the
nomogram presented in figure 6.

Fig. 6. Nomogram used to determine the external
indexing slope angle (
e
)

The internal indexing slope angle
i
, may be analytically
determined with relation:

( ) ( )
b s b
b
b
b
i
k D
R
k
k
k
k

=
1 4
4 3
sin
1 2
1 2
sin (40)

For the quick graphical determination of the internal
indexing slope angle (
i
), there is the nomogram given in
figure 7 [5], [6], [7].


Fig. 7. Nomogram used to determine the internal indexing
slope angle (
i
)
235
3.3. Calculation of some parameters of the cutter
holder head [7]

The nominal diameter of the cutter holder,
s
D , is to be
chosen out of the nomogram shown in figure 3.
The nominal radius of the cutter holder head is:

2
s
s
D
r = (41)

Eccentricity of the cutter head axis:

m s m m s S
r R R r OO e sin 2
2 2
+ = = (42)

Number of the teeth of the reference face gear is:

2
2
2
1 0
z z z + = (43)

Shifting of tool points of cutter head for milling, if
finishing the gear:

i n i cr
m W

= 13 . 0 tg 5 . 2 cos
2

(44)

Actual shifting of the tool points of cutter at the head for
milling, if finishing the gear:

=
cr r
W W , (45)

Rounding has to be done until the value that is the closest
to the normalised value; the positive value will not be
over 0.02m
i
. Shifting of tool points of cutter at the head
for milling, if roughing out in the gear:
r er
W W = (46)

Shifting of tool points of cutter at the head for milling, if
roughing out in the pinion:
r ep
W W = (47)

Shifting of tool points of cutter at the head for milling, if
finishing in the pinion:

r p
W W = (48)

3.4. Calculation of control elements for circular
arc teeth of constant height, model 528
SARATOV

Frontal pitch tooth thickness:
on the pinion:
e
cos
tg
2
2
1
1

n i r
t
m x
m
s

+

= (49)

on the gear:
1 2
t t
s m s = (50)

Intermediate coefficient:
e e
G cos sin
2
1
2
= (51)

Decreasing coefficient of the tooth:
on the pinion:
2 1
1
1 G
R
s
K
t
= (52)
on the gear:

2 2
2
1 G
R
s
K
t
= (53)

Central semi-angle corresponding to the normal tooth
thickness:
on the pinion:

1
3
1
1
cos cos
1

e
t
d
s
= (54)

on the gear:

2
3
2
2
cos cos
2

e
t
d
s
= (55)

Design coefficients:
on the pinion:
6
1
sin
2
1
11

= K i
4
cos 1
1
21

= K (56)

on the gear:

6
1
2
2
12

= K i
4
2
22

= K (57)

Tooth thickness measured on constant span at external
extremity:
on the pinion:

e t cn
K s K s cos
1 11
1 1
= (58)

on the gear:

e t cn
K s K s cos
2 12
2 2
= (59)

Sharpening of the tooth (deviation of the tooth thickness):
on the pinion:

e t
s K h cos
1
21 1
= (60)

on the gear:

e t
s K h cos
2
22 2
= (61)

Height measured on the constant span:
on the pinion:

1 1
1 1
h K h h
a cn
+ = (62)

on the gear:

2 2
2 2
h K h h
a cn
+ = (63)

4. CONCLUSIONS

The work presents the calculation of the main geometrical
elements of bevel gears with circular arc teeth gears and
constant height of the teeth, type 528 SARATOV. The
above presented lead to the following main conclusions:
For this type of gears it is necessary to be specified: the
initial data, calculation of geometrical elements of the
gear and clutch, calculation of some parameters of the
cutter holders for teeth manufacturing as well as
calculation of control elements for circular arc teeth.
236
Some of the advantages in the use of this type of bevel
gear are highlighted: much smoother tooth action,
increase of the gear durability, increase of the face
contact ratio versus straight bevel teeth gears,
possibility to achieve bevel gears with higher velocity
ratios etc..
In teeth gear manufacturing a significant aspect
related to the positional adjustment of the cutter holder
in view of assuring the angles of external indexing
slope (
e
) and internal indexing slope (
i
) which
were determined by analytical or graphical way.
In the case of these kind of bevel gears the specific of
the curved teeth of constant height brings in operation
a significant contribution by equalizing the teeth
loading, especially on the top side of gear bevels.
The work is extremely useful for specialists proposing
themselves to re-design straight teeth bevel gears to
replace such with bevel gears having circular arc teeth.









REFERENCES

[1] CHISIU, Al., a. o., Organe de masini, Editura
Didactica si Pedagogica, Bucuresti, 1981, pp 579-586
[2] GAFITANU, M., a. o., Organe de masini, vol. II,
Editura Tehnica, Bucuresti, 1983, pp 278-330
[3] GRAMESCU, T., Tehnologii de danturare a rotilor
dintate, Editura Universitas, Chisinau, 1993, pp 188-
197
[4] GRIGORE, N. a. o. Metoda grafica pentru
determinarea unghiului de inclinare de divizare
exterior al danturii rotilor dintate conice, Buletinul
Institutului de Petrol si Gaze, Ploiesti, nr.2/1981
[5] GRIGORE, N. a. o. Determinarea grafica a
unghiului de inclinare de divizare interior al danturii
rotilor dintate conice, Buletinul Institutului de Petrol
si Gaze, Ploiesti, nr.1/1982
[6] GRIGORE, N. a. o. Calculul grafic al unghiurilor
de inclinare de divizare al danturilor conice
circulare, Studii si Cercetari de Mecanica Aplicata
nr.6/1982
[7] GRIGORE, N., Organe de Masini, Transmisii
Mecanice, Editura Universitatii din Ploiesti, Ploiesti,
2003, pp 229-278
[8] GRIGORE, N., a. o., Metoda si program pentru
calculul parametrilor de reglaj ai masinii de danturat
conic in arc de cerc 528 SARATOV, Volumul
Lucrarilor Sesiunii Stiintifice 45 ani de invatamant
superior la Galati 28-29 oct. 1993, Galati, 1993
[9] RADULESCU, Gh., a. o., Indrumar de proiectare in
constructia de masini, Editura Tehnica, Bucuresti,
1986, pp 59-84
[10]
* * *
, Cartea masinii de danturat conic in arc de cerc
528 SARATOV









































CORRESPONDENCE


Niculae GRIGORE, Prof. D.Sc. Eng.
PETROLEUM-GAS University of
Ploiesti, Faculty of Mechanical and
Electrical Engineering, General
Mechanics Department, Bucuresti Blvd,
no. 39, Ploiesti 100680, Romania
ngrigore@mail.upg-ploiesti.ro


Adrian CREITARU,
Lecturer. D.Sc. Eng.
PETROLEUM-GAS University of
Ploiesti, Faculty of Mechanical and
Electrical Engineering, General Mechanics
Department, Bucuresti Blvd, no. 39,
Ploiesti 100680, Romania
adrian_creitaru@yahoo.com