Challenges of Generating Helical Gears with SolidWorks: A Review

When it comes to generating helical gears in SolidWorks, one of the biggest challenges users face is achieving an accurate tooth profile. The problem lies in ensuring that the tooth profile is normal to the angle of the tooth, which can be a complex task.

In my experience, I found that using the built-in tools in SolidWorks may not always yield accurate results. However, there are alternative approaches that can be employed to achieve high-accuracy helical gears. One such approach involves modeling the gear in FreeCAD, an open-source nurbs modeler.

Another challenge users face when generating helical gears is ensuring that the tooth profile is normal to the angle of the tooth. To overcome this issue, it is essential to create a closed polycurve and sweep it along two curves as described in step 6. This approach allows for greater control over the outside diameter of the gear, which can be critical in certain applications.

In addition to these challenges, users must also be aware that different approaches may 'look the part' on-screen but have their inaccuracies. Therefore, it is essential to carefully evaluate each method and choose the one that best suits your needs.

For those who are interested in learning more about generating helical gears in SolidWorks, I recommend checking out Loganvsky and Khmarova's paper '3D Model of Geometrically Accurate Helical-Gear Set' (Procedia Engineering 150:734-741). This paper provides a step-by-step guide to producing high-tolerance helical gears using SolidWorks.

While there are various approaches to generating helical gears, none may provide truly accurate results for manufacturing highly-loaded gears. However, by carefully evaluating each method and choosing the one that best suits your needs, you can achieve high-accuracy helical gears in SolidWorks.

Generating helical gears in SolidWorks can be a complex task, requiring careful attention to detail and a thorough understanding of the underlying principles. By using alternative approaches such as FreeCAD or Rush Gears, users can overcome the challenges associated with generating accurate tooth profiles. Whether you are working on historical machinery documentation or simply need to design high-accuracy helical gears, this article provides valuable insights into the challenges and solutions involved in generating these complex components.

Solidworks helical gear generator