Design and Development Model of Spiral Bevel Gear with Minimized Weight

Gears are used in most types of machinery and vehicles for the transmission of power. Bevel
gears are widely used because of their sustainability towards transferring power between non-
parallel shaft at almost any angle or speed. Drilling machines are used to cut woodwork
pieces for the purpose of making furniture, Casting patterns, wooden seat designs, and wood
prototyping, among other applications. In that machine, a set of spiral bevel gears is used for
power transmission from the motor to the tool. The handheld tool's weight and continuous
vibrations make it difficult to operate the machine for extended periods. Additionally, the
power consumption per unit cut is very high, and vibrations lead to inaccuracy in cutting and
errors in profile shape. Thus, the methodology used in the study involves carrying out tests on
three sets of bevel plain gears: (i) no weight reduction, (ii) weight reduction achieved by
providing recesses on the gear face, and (iii) weight reduction achieved by providing equi-
spaced holes on the face—comparative performance analysis of the gears by load to derive
the optimal performance of the gears. The optimization of spiral bevel gears can reduce
weight, material usage, process time, and production costs.
Keywords: Weight reduction, Face recess, Face holes, and Vibration analysis