If you can forward me the measurements that you have taken, Iwill run some numbers for you and let you know what the helix angle "calculates" to be...
Also, could you let me know what the helical gears are used for? Some gearbox manufacturers modify the pitch of the gear to try and capture the...
The isze of the chamfer depends on the pitch. We make some very large gears with a 1/4 X 45 chamfer. We also make smaller gears with 1/8 or or even a 1/32 chamfer.
Some maufacturers will intentionally leave splines soft on internal couplings. They will act as a fuse in the drive train. They will give or wear faster than the more expensive mating parts.