Abstract: According to the spatial gearing theory, the mathematical model for working pitch cone design of intersected beveloid gears is created in order to confirm the working cone angles and the helix angles as well as the mounting distance of the two meshing gears. The formulas to determine the transition from point contact to line contact are derived to achieve the approximate line contact. Besides, the formulas to determine the effective tooth width of the two sides of the working pitch circle are derived. Based on the relationship of the parameters of the beveloid gears using in intersected axis transmission, the analyses of the effects of key design parameters on the angle between the first principle directions(FPD) as well as on the contact ratio are conducted. The fundamental design parameters of one case for the proposed beveloid gear drive in line contact is derived and the loaded tooth contact analysis is performed using the finite element method. The conclusions indicted that the intersected beveloid gears engage with each other in line contact which is considered the geometry design approach assuming line contact. Also, the area of the contact pattern is approximately 50%. A practical tooth bearing test is conducted to demonstrate the proposed design procedure and the experimental results compared well with the simulation.

Key words: Beveloid gears, Intersected axis, Line contact, Meshing contact area, Test, Working pitch cone design