Spiral Bevel Gears - Baja Racing
Custom designed spiral bevel gears for our car's front gearbox.
New component built for our 2023-2024 propeller shaft 4WD system.
Designed in KISSsoft & Solidworks
Machined from heat-treated AISI 8620
19 x 75 Spiral Bevel Gears
Pinion Design
• 19 tooth gear head designed in
KISSsoft drivetrain software
• Journal (20mm) for double row
angular contact bearing
• M17x1mm threaded for bearing
lock nut for axial retention
• Custom spline for u-joint hub
attachment
Ring Gear Design
• 75 tooth gear head designed in
KISSsoft drivetrain software
• Ring gear carrier (6061-T6)
pressed in center & bolted on rear
• Center bore for GMN sprag clutch
bearings
• Sprag sleeve (4130 Chromoly) for
keyless clutch mechanism
Quarter cut section view of the internal positioning
Gearbox Design
• Custom billet 6061-T6 gearbox housing
• Integrates with gears through ring gear
carrier & pinion circlip
• Gear output towards CV driveshafts
Cross section view along the meshing plane
Analysis
• KISSsoft/KISSsys modular
calculations & simulations
• Gleason's proprietary software
for theoretical verification
• Max Contact Stress: 295.4 ksi
---> FoS: INFINITE
• Max Bending Stress: 202.6 ksi
---> FoS: 1.282 (500 ft-lb)
---> FoS: 18.5 (1.3E6 cycles)
Failure Analysis
• Problem: Improper installation caused
gearset failure due to axial slip along the
pinion thread
• Solution: Add and properly torque a
nyloc bearing nut made from the proper
manufacturer
Inner tooth faulure caused by axial pinion slip
