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A "stronger" material will not necessarily improve resistance to tooth bending failure. The most important thing to consider is the type of loading, then figure out the best material to use. Analyse the fracture surfaces of the failed components to determine the type of bending failure that has...

Powershift transmissions do not have mechanical linkages (yokes, rails, detents, etc) to perform the change-of-gear function. They are constant mesh gearboxes that have individual clutch packs for each gear. The clutch packs are hydraulically activated. There is no synchromesh. Earlier machines...

Most, if not all, geared vertical spindle drilling machines have gearboxes that operate in the horizontal position. The uppermost gears and bearings are generally not lubricated throughout the life of the machine as the oil simply doesn't get to those areas. I've seen drills up to 3.5KW that...

I forgot to add; using a standard 2.25M hob for pre-grinding operations will result in a clearance height that is less than standard (not 2.25 x module). The reason for this is because a pre-grind cut will require stock to be left behind for the grinding operation. This means that the hob will...

The biggest problem you're going to face is that the 2.25 'standard' profile will not have protuberance added to the hob's profile. Without the undercut that the protuberance creates and without the extra clearance; grinding the profile will leave a grinding-step near the root. The step will...

For 3.175mod, 50 teeth, quality grade A5

'dT' is the Tolerance Diameter in mm. From page 8 of the AGMA 2015-1-A01 standard: "The diameter located one normal module below the design outside diameter, thereby being approximately at mid-height." dT = Do - 2mn Do = design outside diameter, mm. mn = normal module, mm. AGMA released a...

This is not *really* correct. Try to stop thinking of levers or pulleys when looking at gearing problems. It's the number of teeth, not the radius length, that determines the torque ratio.

There are no rules, as profile shifting requires a life-time of experience to grasp. Generally however, a more balanced specific-sliding ratio is what gear designers will look for with some designers looking for slightly more recess action than approach action. Try to learn what these terms mean...

Perhaps you could re-read the posts. The spec is calling for a lead correction of 32', +/- 4'. I don't know of an EDM that could replicate that, let alone applying it to a profile which has, no doubt, already been machined without the correction.

A very good break-down, with explanation, of this transmission - https://youtu.be/dqM3YXEf1js Check out the other videos on the guy's channel, well worth the effort.

I can help you by providing a DXF but I'm not prepared to provide my time for-free.

As you seem to be unable to provide all of the info that's been asked for; the only thing I can suggest is to re-make the parts. With such a small quantity involved; I doubt that there would be a solution that would end up being more cost effective than simply re-making the parts.

First thing that comes to mind is a torque converter, or fluid coupling.

If both the internal & external profiles have been machined to the same dimensions; there aren't all that many options for you. Due to tooth-tooth spacing errors as well as profile error; the transition fit you describe is more than likely going to be an interference-type fit for the majority of...

More info would be helpful. Spline data, drawings, material/heat treatment specs and parts quantity.

Sounds like it might be time for you to engage the services of a gear-design consultant.

Beveloid gears are quite common, although I'm not sure what the 'V-Drive' is that Mike's referring to. The examples below are from Audi & Porsche. I've also seen these gears in stern-drives of boats and, would you believe, in the drive of a 1930's-built rotating platform for steam locomotives.

For those unable to open the OP's STEP file.................

The gearing you're after is generally called 'tapered spur' or 'tapered helical'. The correct terminology is 'beveloid'. In your case you need a spur gear that meshes with a tapered helical. The example below shows a set where the shaft angle is 10deg and the cone angle of the pinion is 7deg...