Each circle had a line starting at the center point and extended until it intersected the other line. To obtain the cone angles, a sketch was created on the front plane with 3 lines creating a right-angled triangle. The sketch with the 20mm circle had a vertical relation to the center of the bigger circle and the edges of the circles are tangent. The 40mm circle was sketched on the top plane and the 20mm gear was sketched on a plane parallel to the right plane and tangent to the edge of the 40mm circle.
To start, I made two orthogonal sketches with the pitch diameter of each gear (20mm and 40mm). The first step was to get the gear ratio I wanted and for this example, it is 20/40 or 1/2. I wanted to use SOLIDWORKS and do as simple of calculations as possible. There are equations to calculate specifications of the bevel like the cone angles of the gears, tooth, face width and cone distances.
Recently, I ran into a scenario where I had to design some custom-sized gears and found a creative way to make a beveled gear that I thought I should share.
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