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When two main shafts are non-parallel, the gear transmission between them is called an intersecting axis gear transmission, or bevel gear transmission. Bevel gears are transmission components designed specifically for transmission between intersecting shafts. Their tooth lengths and shapes vary, including spur, helical, and arc-shaped. Straight bevel gears have attracted considerable attention due to their wide range of applications. Although helical bevel gears were once less popular due to machining difficulties, they are now being gradually replaced by spiral bevel gears. Although spiral bevel gears require specialized machine tools, they offer smooth transmission and high load capacity, making them widely used in applications such as automobiles, tractors, and coal mining machinery.
Among the many types of bevel gears, straight bevel gears, with their simple tooth profile and excellent transmission performance, have become key components in many mechanical systems. However, this type of transmission suffers from poor operational smoothness and is generally suitable for average pitch speeds of less than 5 m/s. They also have relatively low load capacity. However, their ease of manufacture makes them widely used.
When the main shafts intersect and are not parallel, the gear transmission used is called a helical bevel gear transmission. This transmission method is widely used in the automotive, aerospace and other fields, and is of great significance for improving the performance and efficiency of mechanical systems.
Also known as spiral bevel gear transmission, they feature a helical tooth meshing characteristic of progressive contact and a large overlap ratio, resulting in smooth transmission, low noise, and high load capacity. The minimum number of teeth can be as low as 5, allowing for larger transmission ratios and smaller mechanism dimensions. Sharing many similarities with cylindrical gear transmission, circular arc bevel gear transmission achieves efficient transmission through pure rolling of the pitch cone, making transmission between gears smoother and ensuring smooth and efficient transmission.
The following table can help you further understand these three Bevel Gear transmission methods. Raydafon welcomes you to purchase them.
| Feature | Straight Bevel Gears | Spiral Bevel Gears | Zerol Bevel Gears (Curved Tooth) |
| Tooth Design | Straight teeth tapering toward apex | Curved teeth with spiral angle (25–40°) | Curved teeth with 0° spiral angle (hybrid) |
| Contact Pattern | Point contact → Gradual engagement | Line contact → Smooth rolling action | Line contact (similar to spiral) |
| Load Capacity | Low (stress concentration at tooth ends) | Highest (distributed contact + gradual mesh) | Moderate (higher than straight, lower than spiral) |
| Noise & Vibration | High noise at speed (sudden impacts) | Quietest (continuous engagement) | Low noise (smoother than straight) |
| Efficiency | 90–95% (sliding friction) | 95–99% (rolling-dominated contact) | 92–96% |
| Axial Thrust | Low (minimal axial force) | High (due to spiral angle) | Near-zero (0° helix avoids thrust) |
| Manufacturing | • Simplest (form-cut)• Low cost | • Complex (face-milled)• High cost | • Moderate complexity• CNC grinding needed |
| Applications | Low-speed:• Mechanical clocks• Hand tools | High-performance:• Automotive differentials• Helicopter transmissions | Thrust-sensitive systems:• Marine gearboxes• Printing press drives |
| Key Advantages | • Low cost• Easy assembly | • High strength/smoothness• Compact size for power | • Quiet + no axial thrust• Easier mounting |
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Luotuo Industrial Area, Zhenhai District, Ningbo City, China