Preliminary Determination of Helix Angle for a Helical Gear Pair

Abstract
This paper presents an approach for the determination of the helix angle for a heavy duty helical
gear pair. The helix angle is very important parameter in the design of the gear pairs which
ultimately affects the overall design and working of the gearbox. The approach for the
determination of helix angle using Grey Relational Analysis has been investigated. The paper
identifies that the GRA approach has been found compelling for the Helix angle determination
model for gear design. The paper presents the preliminary helix angle determination using
GRA for 3-stage helical gearbox for Banbury Mixer with multiple power transmission paths.
Introduction
The gearbox plays very important role in power transmission industry for the fulfilment of
torque and speed requirement for an application. The design and development of an
engineering product demands the decisive approach for the selection of the basic parameters,
which is very vital task.
There are various components in a gearbox like gears, shafts, bearings etc. The gear pairs are
main power transmitting members in the gearbox. Some of the parameters of importance for
the gear pairs are Helix angle, Hand of helix and Reduction ratio.
One of the decisive parameter in the design of gear pairs is helix angle, which affects the
various parameters like gear weight, contact ratio, axial forces on bearings etc. which will
influence the overall design of the gearbox. Due to this reason, the helix angle should be
selected judiciously.
The General Layout of the gearbox is presented in the diagram:

Literature Review
Tyler G. Hicks [1]under The helical gear Layout analysis suggests the calculation procedure
under which in the preliminary layout of gear drives, the designer must determine if the selected
parameters i.e. Gear ratio, Diameteral pitch, centre distance are suitable for the proposed layout
which is followed by calculation of specific helix angle. The comparative calculation approach
is suggested for the calculation of helix angle for crossed helical gear pair with equation.
Amlana panda, Ashok kumar sahoo and Arun kumar rout [2] has studied a case of multi
attribute decision making parametric optimization and modelling in hard turning using ceramic
insert through grey relational analysis. The speed, feed and depth of cut has been considered
as influencing parameters. The orthogonal array of taguchi method is used in combination with
grey relational analysis for finding the optimal solution for the same.
Since uncertainty always exist in any system, the solution is always somewhere in the middle
somewhere between extremes, somewhere in grey area. Grey analysis then comes to a clear
state of statements about system solutions. [3]
The selection of helix angle is an important criteria in gear design. However, prior studies have
failed to propose any specific methodology for preliminary determination of the helix angle for
parallel helical gear pair. The selection of helix angle in helical gear design also consists of
multiple attribute system. Hence, the investigation is required in the direction of the application
of GRA in determination of the helix angle.

Methodology
Step 1 : Study of client’s specification
Step 2 : Determination of general layout
(Type of gearbox, Stage wise reduction ratio, Design torque)
Step 3 : Selection of helix angle influenced parameters
Step 4 : Determination of helix angle influenced parameters for different helix angle
Step 5 : Grey relational analysis for multi attribute system ( Maximization or Minimization )
Step 6 : Analysis of GRA result – Rank wise arrangement of the alternatives
Step 7 : Check for safety and system requirement
Step 8 : If safety and system requirements fulfilled then go to step 10. Otherwise go to step 9.
Step 9 : Select next ranked alternative and go to step 7.
Step 10 : Final Selection

Design Computation

1. Client’s Specifications
Motor Pmin Pnominal Pmax Period of operation : continuous
Power 100 kW 1250 kW 1500 kW No. of starts : 1 to 20/hr
Motor Nmin Nnominal Nmax
Length of gearbox = 3 m or 3000 m
Speed 100 RPM 1000 RPM 1500 RPM
C.D. between two output shafts : 565.5 mm
Absorbed Pmin Pnominal Pmax
No. of Input = 1 , No. of Outputs = 2
Power 100 kW 1250 kW 1500 kW
Parallel shaft orientation ( I/P & O/P )
Machine Nmin Nnominal Nmax
Speed 0/4 RPM 40 RPM 60 RPM Reduction ratio : 25 ± 3 %

Ratio Selection:
From standard R20 series, Selected Pair : 2.5 , 3.55, 2.8 For stage 1,2 and 3 respectively.
Two outputs requires rotation in opposite direction with same speed, Reduction Ratio = 1.
2. Torque calculation
The Equivalent torque is determined with reference to DIN 3990 Standard. [4]

% Torque Time ( Sec)

250 10
150 20
100 120
10 30
Mixing Cycle Time: 3 Minutes
Heat Pitting Tooth Root
Treatment p NLref p NLref
Case 5x 3x
6.61 8.738
Carburised 107 106
1
n1 ∗ T1 p + n2 ∗ T2 p + n3 ∗ T3 p + ⋯ p Equivalent Torque Design Torque
Teq = ( )
n1 + n2 + n3 + ⋯ Shaft Torque (N.m) Torque (N.m)
1 19540.81343 19540.81343
Where,
2 48852.03358 48852.03358
ni is number of load cycle of the bin i
3 173424.7192 173424.7192
Ti is the torque of the bin i
4 485589.2138 267074.0676
P is the slope of the Wohler-damage line
5 485589.2138 267074.0676

3. Helix Angle Determination

The helix angle determination is an important criterion of design of helical gears as the gear
dimensions, centre distance of drive, thrust forces and other parameters dependent on its
magnitude and orientation. Hence it should be judiciously chosen.
For normal application, the Value of helix angle should lie in the range shown as follows:
Helix Angle (β) = 8 to 20 (Single Helical Gear Pair)
The Helix angle should not cross 30 to avoid a large resultant axial thrust. [5]
On lower side, it should not be below 8 as otherwise the advantages offered by helical
gearing become marginal.
Also it is desirable to have helix angle a whole number as it simplifies machine setting for
cutting gears as well as finishing processes.

There is no any specific methodology or guidelines available for determination of stage wise
Helix angle. The approach of GREY RELATIONAL ANALYSIS method for MULTIPLE
PARAMETERS is applied to preliminary determination of helix angle. Grey relational
analysis does not attempt to find out best solution, but does provide techniques for
determining a good solution, an appropriate solution for a real world problem.
The Grey Relational Analysis (GRA) can provide a solution of a system when the model is
unsure or the information is incomplete. It provides an efficient problem solution to
uncertainty, multi-input, and discrete data problem.
Here for preliminary determination of helix angle, using GRA model we have considered
the effect of helix angle on different gear parameters. We found three parameters of main
importance:
1. Contact Ratio (C.R.) : Which should be maximum, Hence (1/C.R.) should be minimum
Higher the contact ratio, more number of pairs of teeth will be in engagement
simultaneously which will lead to smoother action of gears.
2. Weight : Which should be minimum
Reduction in cost of material and manufacturing cost.
3. Fa/Fr Ratio : Which should be minimum
Lower the Axial force to Radial force ratio, the required axial load carrying capacity of
bearing reduces. Hence the lower contact angle bearing can be used.

The Contact Ratio, Geometry, Fa/Fr ratio is calculated with reference to Handbook of Gear
Design. [5]

Considerations in GRA:
1. All parameters are given equal weightage
2. The face width and module are variable parameters.
3. 8 Helix angle being limiting value of permissible range is neglected.

The preliminary determination for the helix angle is based on Grey Relational Analysis.
Which suggests the rank wise best choices for the results. As the design procedure
progresses and if manufacturing considerations do not permit the same results, the next rank
wise choice is selected.

In this case, Manufacturing & Design considerations are as follows:

1) Face Width / Centre distance Ratio should be in limit of 0.35 to 0.55
2) The Centre distance of the last stage is fixed, which is 565.5 mm.
3) The Contact ratio should be more than 2.
4) The maximum length of the gearbox permitted is 3000 mm.
Grey Relational Analysis (For Minimization Function)

The steps for Grey Relational Analysis followed for the determination of optimum helix
angle are as follows: [2]
Step-1
The first step is to normalize the data for avoiding different units and to reduce the
variability. This is required as the variation of different data differs from other. A suitable
value is derived from the original value, and will make the array between 0 and 1. In general,
the method converts original data to a comparable data. For responses to be minimum,
following formula is applied:
max 𝑥𝑖 (𝑘) − 𝑥𝑖 (𝑘)
𝑥𝑖∗ (𝑘) =
max 𝑥𝑖 (𝑘) − 𝑚𝑖𝑛𝑥𝑖 (𝑘)
Where, i = 1,…, m and k = 1,…,n., m is the number of experimental data and n is the number
of responses. xi(k) denotes the original sequence, xi*(k) denotes the sequence after the data
pre-processing, max xi(k) denotes the maximum value of xi(k), min xi(k) denotes the
minimum value of xi(k), and x is the desired value.

Step-2
Grey relational coefficient ξi(k) is calculated from the normalized values by the following
Formula as follows:
∆𝑚𝑖𝑛 + ξ∆𝑚𝑎𝑥
ξ𝑖 (𝑘) =
∆𝑜𝑖 (𝑘) + ξ∆𝑚𝑎𝑥

Where, ∆𝑜𝑖 is the deviation sequence of the reference sequence and the comparability
sequence.
∆𝑜𝑖 = ‖𝑥0 (k) −𝑥𝑖 (k)‖
and where x0 (k) implies the reference sequence and xi (k) termed as comparability
sequence. ∆𝑚𝑖𝑛 And ∆𝑚𝑎𝑥 represents the minimum and maximum values of the absolute
differences ( ∆𝑜𝑖 ) of all comparing sequences. Ζ is distinguishing coefficient, the range for
value is between 0 and 1. Usually, the value of ζ is taken as 0.5 for the calculation.

Step-3
Grey relational grade (GRG) is calculated as follows:
n
1
γi = ∑ ξi (k)
n
k=1

Where, γi is the required grey relational grade for ith number of experiment and n = number
of response characteristics. The grey relational grade represents the level of correlation
between the reference sequence and the comparability sequence. It is the overall
representative of all the quality characteristics.

Step-4
The rank is given to all the data sets from the calculated Grey relational grade.
 Results of Grey Relational Analysis:
Stage 1 Stage 2
Helix Helix
Rank Weight(kg) 1/C.R. Fa/Fr Rank Weight(kg) 1/C.R. Fa/Fr
Angle Angle
8 1 656.501 0.3511 0.3740 8 1 2487.343 0.3551 0.3824
9 2 577.268 0.3558 0.4200 12 2 2512.544 0.3611 0.5712
12 3 586.910 0.3613 0.5710 11 3 2786.639 0.3573 0.5242
10 4 712.677 0.3542 0.4770 9 4 3278.850 0.3565 0.4298
11 5 642.806 0.3595 0.5240 10 5 2924.379 0.3589 0.4771
20 6 563.434 0.3832 0.9400 18 6 2483.557 0.3720 0.8490
19 7 603.679 0.3783 0.8950 17 7 2637.299 0.3679 0.8032
18 8 622.639 0.3746 0.8490 16 8 2713.585 0.3686 0.7573
13 9 846.157 0.3637 0.6180 13 9 3273.417 0.3628 0.6180
14 10 789.746 0.3644 0.6650 14 10 3126.522 0.3639 0.6645
17 11 661.554 0.3720 0.8030 15 11 2890.558 0.3670 0.7107
16 12 682.295 0.3706 0.7570 21 12 2947.430 0.3830 0.9846
15 13 714.532 0.3709 0.7110 19 13 3258.137 0.3746 0.8944
21 14 824.978 0.3828 0.9850 20 14 3073.765 0.3801 0.9396
Selected Helix angle : 9 Selected Helix angle : 12

Stage 3
Output Stage
Helix Rank Weight 1/C.R. Fa/Fr
Angle (i) The Specialty of the Final stage is that, the centre
8 1 6348.622 0.3569 0.3820 distance is fixed. So as to fulfil this requirement,
12 2 6218.269 0.3631 0.5710 the combination of parameters like Helix angle,
9 3 8154.452 0.3595 0.4300 module, face width, No. of teeth on pinion all
10 4 7374.460 0.3597 0.4770 together should be checked.
11 5 6665.377 0.3618 0.5240
18 6 5978.623 0.3759 0.8490
(ii) The final selection of helix angle in case of fixed
17 7 6216.127 0.3748 0.8030
centre distance should be done by considering the
16 8 6601.470 0.3719 0.7570
variation in teeth and modules in selected
15 9 6969.894 0.3697 0.7110
13 10 7931.858 0.3662 0.6180
combination such that the value of addendum
14 11 7468.374 0.3671 0.6650 modification coefficient lies in desired range and
19 12 8521.673 0.3785 0.8950 the desired safety parameters are achieved.
20 13 8115.313 0.3823 0.9400
21 14 7825.906 0.3845 0.9850 Some of the results for the output stage are shown in
Selected Helix angle : 12 the table:
Output Stage
Module Module Helix Angle Rank Face width 1/C.R. Fa/Fr Z1 Deviation(mm)
15.8603 16 11 1 300 0.4890 0.524 35 4.98135
17.8433 18 12 2 305 0.4742 0.571 31 4.96605
19.8254 20 11 3 370 0.4570 0.524 28 4.98135
19.7551 20 12 4 336 0.4602 0.571 28 7.01073
15.9117 16 10 5 328 0.4854 0.477 35 3.13890
18.0173 18 9 6 412 0.4675 0.43 31 0.54446
19.9478 20 9 7 458 0.4523 0.43 28 1.48047
17.9648 18 10 8 370 0.4692 0.477 31 1.10805
17.9068 18 11 9 333 0.4724 0.524 31 2.94392
19.8896 20 10 10 410 0.4545 0.477 28 3.13890
Selected Helix angle : 11
 References

[1] T. G. Hicks, "Helical-Gear Layout Analysis," in Handbook of Machanical Engineering

Calculations, Second Edition, McGraw Hill Education.

[2] A. K. S. A. K. R. Amlana Panda, "Multi Attribute Decision Making Parametric

Optimization and Modelling in Hard Turning using Ceramic Insert Through Grey
Relational Analysis ; A Case Study," Decision Science Letters, vol. 5, pp. 581-592, 2016.

[3] "Wikipedia," [Online]. [Accessed 17 July 2019].

[4] DIN, "DIN 3990 : Part 6 Calculation of Load Capacity of Spur and Helical Gears :
Calculation of Service Life Under Variable Load". West Germany .

[5] G. Maitra, Handbook of Gear Design, McGraw Hill Education.