Spherical conjugated Differential Bevel Gears

Here is a design family of a bevel gear set for application in differentials. The bevel gears are spherical conjugated which means that the gears are defined and limited by a spherical surface. The torque capability depends on the size of the sphere and the amount of pinion gears. So I made a variation with following parameters:

- Ø60mm, 4 Pinions, z1=14, z2=10 - Ø80mm, 3 Pinions, z1=15, z2=10 - Ø90mm, 2 Pinions, z1=13, z2=9 - Ø135mm, 2 Pinions, z1=15, z2=11

The gears are additionally designed with a stronger heel and toe geometry which is needed for application in differential. This geometry can only be made whe forging the gears and not with a standard cutting process.

Those gearsets can be used in the most common vehicles started with a formula student race car up to a mid size truck.