I have used GearGen written by Thomas Anagnostou with great success generating bevel gears up to about 24 in. in diameter. The design for the current iteration of the project requires a larger diameter bevel gear; the pitch diameter is now in the neighborhood of 51.20 inches. Given the 45:1 gear ratio and the 400 tooth limit in GearGen, I’m afraid that the pinion hasn’t enough teeth to take the stresses imposed.
Can GearGen be modified to handle such a large diameter, small tooth design? If not, is there another script that can? The link below is to a quick and dirty representation of what I’m working on.