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Introduction To Forging Bevel Gears – Types, Applications & More

Even though forging bevel gears and gear blanks have been around since the 1960s, It’s been discovered that a surprising amount of engineers and designers are unaware of the benefits of forging over alternative forming techniques and production methods. They are frequently uninformed of the distinctions between forgings and other formed products, like castings. Forgings are heated to a maximum of 2450 degrees Fahrenheit (depending on the grade) for hot forging and then molded to obtain the appropriate component dimensions.

This article covers all you need to know about bevel gears. and the applications of forging bevel gears.

What are Bevel Gears?

A Bevel gear is a toothed rotating mechanical device that is used to transfer mechanical energy or shaft power between shafts that cross at an angle or perpendicularly. The shaft power’s axis of rotation changes as a result of this. Aside from this, bevel gears may also increase or reduce the torque while causing the angular speed to change in the opposite direction.

A truncated cone can be used to represent a bevel gear. Teeth are milled on the lateral side, which interlocks with other gears having their own set of teeth. The gear that transmits shaft power is known as the driver gear, while the gear that receives power is known as the driven gear.

Types Of Bevel Gears:

Bevel gears are classified by the tooth profile and orientation of their teeth. Spiral and hypoid bevel gears, for example, are more sophisticated kinds that arose from the advancement of manufacturing methods like CNC machining.

Straight Bevel Gears

This is the most basic type of bevel gear. When the gear is expanded, the teeth form a straight line that meets at the axis of the gear.

Spiral Bevel Gears

The most complicated type of bevel gear is this one. Spiral gears have curved and oblique teeth, as opposed to straight bevel gears, which have straight teeth.

Zerol Bevel Gears

Gleason Works trademarked a straight bevel gear, and this kind is a variation of it. The teeth of Zerol bevel gears are bent in a longitudinal manner. The profile of these gears is similarly similar to that of spiral bevel gears.

Hypoid Bevel Gears

This is a special type of bevel gear where the axes of the shafts are not intersecting or parallel. The distance between the two gear axes is called the offset. The teeth of hypoid bevel gears are helical, similar to spiral bevel gears.

Miter Bevel Gears

This is a 1:1 gear ratio bevel gear, which means the driver and driven gears have the same number of teeth. The only use of this kind is to rotate or change the axis.

Applications Of Bevel Gears:

Bevel gears are one of the simplest and most efficient ways to change the rotational axis of a drivetrain. The type of bevel gear utilized, as well as the manufacturing and finishing methods, is determined by the application. Some of the uses for bevel gear systems are listed below.

  • Automotive
  • Heavy Equipment
  • Industrial Plant Equipment
  • Aviation
  • Marine

The advantages of forging bevel gear manufacturing include not only material savings, energy savings, and high efficiency, but also improved wear resistance, corrosion resistance, and root flexural strength of gear, as well as improved fatigue performance. Precision forging straight bevel gear production line may cut production costs by 20% to 40% when compared to processing.