Mechanical and Mechatronics Engineering Program

Design Project A (MECH4913)

Mini Project (2018/2019)

Differential Gearbox
 ABSTRACT

The main objective of this project is to perform mechanical design of differential gear
box and analysis of gears in gear box. We have taken grey cast iron and aluminum
alloy materials for conducting the analysis for SolidWorks Simulation. Presently used
materials for gears and gears shafts is Cast Iron, Cast Steel. So, in this presentation we
are checking as the aluminum can be the other material for the differential gear box for
light utility vehicles so, we can reduce the weight.
 CONTENTS
CHAPTER 1. INTRODUCTION CHAPTER 4. DESIGN ANALYSIS AND RESULT

 Introduction  DESIGN OF DIFFERENTIAL GEAR BOX

 Whys the Differential Gear Is Used?  ANALYSIS OF DIFFERENTIAL GEAR BOX
 Problem definition  EXPERIMENTAL RESULTS
 Design concept  Total Deformation of Grey Cast Iron
 How Differential Works  Total Deformation of Aluminium Alloy
 Cost analysis
CHAPTER 2. LITERATURE REVIEW
CHAPTER 5. CONCLUSION
 Differentiation
 Types of differential

CHAPTER 3. METHODOLOGY
 INTRODUCTION
CHAPTER 1

The Differential gear is a part for all four

wheelers, wheel reserved the power from
engine to gear box then by drive shaft to
differential gear. Differential innovation
was created hundreds of years prior and is
viewed as a standout amongst the most
astute developments human reasoning
has ever delivered the car differential
enables a vehicle to turn a corner while
shielding the wheels from sliding.
WHY THE DIFFERENTIAL GEAR IS USED?
CHAPTER 1

The Wheels are taking the force power

from the engine by a drive shaft. The
wheels that get power and make the
vehicle push ahead are known as the
drive wheels. The fundamental capacity
of the differential rigging is to permit the
drive wheels to turn at diversely RPMs while
both are getting power from the motor
engine, Power from the engine is flowed
to the wheels via a drive shaft.
 WHY THE DIFFERENTIAL GEAR IS USED?
CHAPTER 1

Consider these wheels, which are

negotiating a turn. As we see It is clear to
as that the left wheel has to travel a more
distance compared to the right wheel; this
means While taking a right turn the left
wheel has to travel more distance more
speed to left wheel.
WHY THE DIFFERENTIAL GEAR IS USED?
CHAPTER 1

This implies the left wheel needs to pivot at

a higher speed contrasted with the other
wheel. On the off chance that these
wheels were associated utilizing a strong
shaft, the wheels would need to slip to
achieve the turn. This is actually where a
differential proves to be useful. The quick
component in a differential enables the
left and right wheels to turn at various
RPMs, while transferring capacity of power
to the two wheels.
 PROBLEM DEFINITION
CHAPTER 1

The differential outfit oil lubricates up the

ring and pinion adapts that give control
from the drive shaft to the wheel axles.
Keeping the oil in your differential spotless
and transforming it all the time is similarly
as vital as your motor's oil.

After some time, if the oil turns sour or you

have a break in your differential, the metal
will crush on metal and will wear out the
surfaces. This makes high measures of
warmth from grinding, which will debilitate
the riggings and lead to disappointment,
overheating, or consuming.
PROBLEM DEFINITION
CHAPTER 1

The oil should be changed each 30,000 to

50,000 miles, except if your proprietor's
manual states different.
PROBLEM DEFINITION
CHAPTER 1

Commotion: Sound Nuisance when

decelerating

Cause: Loose pinion bearing preload

Commotion: Sound Nuisance when

acceleration at any speed

Cause: Worn back pinion bearing or worn

apparatus set
PROBLEM DEFINITION
CHAPTER 1

Commotion: Sound Nuisance usually when

giving full power acceleration

Cause: Worn rigging set because of an absence

of oil or over-burdening

Commotion: when driving at 10 to 20 km/h

Cause: Worn pinion direction

 DESIGN CONCEPT
CHAPTER 1

The Power from the motor engine is

transferred to the ring gear through a
pinion equip. The ring gear is associated
with a spider gear. The Motion from the
pinion gear is transferred to the spider
gear
DESIGN CONCEPT
CHAPTER 1

The spider gear is the most important of

the differential, and unique notice ought
to its will be around its revolution.
There for spider gears is allowed to create
two sorts of pivots, some alongside
revolution of ring gear in addition to the
another without anyone else hub turn.
The spider gear is allowed to make two
different of revolutions.
HOW DIFFERENTIAL WORKS
CHAPTER 1
 DIFFERENTIATION
CHAPTER 2

Differential is a very significant part of an

automobile as a component transmits
engine power to the wheels. The power of
the engine is conveyed by the rearmost
propeller shaft to the wheel, first it
changes direction by differential rotation,
and then it is transferred to the rear axle
shafts to the back wheels.
 TYPES OF DIFFERENTIAL GEARS
CHAPTER 2

Locking differential

A locking differential is made to overcome

the key limitation of a typical open
differential by fundamentally “locking" the
two wheels together on an axle as if on a
mutual shaft. This services both wheels to
turn in unison, irrespective of the traction (
or lack thereof) available to each wheel
individually.
 TYPES OF DIFFERENTIAL GEARS
CHAPTER 2

Limited Slip Differentials

A Limited Slip Differential( LSD) is a kind of

differential that allows its two yield shafts
to rotate at different speeds, but limits the
maximum difference between these two
shafts.
 METHODOLOGY
CHAPTER 3

During this design project we would like to followed a simple approach of designing for
Differential gear box. We will do many steps:

1. Introduction and defining the problem

2. design the Differential gear in SoildWorks
3. Print our design in 3 D, finite element and do manufacture for bevel gear only
4. Analyzing and selecting a feasible solution
5. Discuss our result and tray to develop process for our project.
METHODOLOGY
CHAPTER 3
 METHODOLOGY
CHAPTER 3

The differential Gearbox have two

type two type of gears single
helical gear and bevel gears. The
single helical gears connecting
parallel shafts

The object of the helical gear is to

balance out the end thrusts that are
induced in single helical gears when
transmitting load.
 METHODOLOGY
CHAPTER 3

These gears are called bevel gears

and the arrangement is known as
bevel gearing. The bevel gears, like
spur gears may also have their teeth
inclined to the face of the bevel, in
which case they are known as
helical bevel gears.

After design this two gears we print

in 3 Dimension, and use the shape
of bevel gear like frame to do
manufacturing in the lab. The
material selection is one of the
important parts in the designing
procedures, we will explain later
about it.
 METHODOLOGY
CHAPTER 3
The project starts by going through the problem and defining it, then the introduction of
designing process and the introduction of a differential Gearbox. Then the stage of
literature review and research comes on the project topic which is design and analysis of a
comfortable differential Gearbox.

Once the relevant information is gathered, we start the step of designing from the
information and literature review a suitable design that satisfies the objective of the project
is designed.

In the analysis step, a simulation of the differential gearbox is performed and the failure
analysis tool will then be selected on the material to identify strengths and weaknesses to
determine the appropriate material type better.

In any case, this project contains a visual presentation explaining the steps and stages of
the work and has been printed as a 3D object and we do manufactured in the university
laboratory
DESIGN OF DIFFERENTIAL GEARBOX
CHAPTER 4

Modelling details

To determine the structural analysis

on the differential gear box. First, we
have to create a model of
differential gear box in modelling
software’s. We have the assembly
of differential gear box in
SOLIDWORKS.
 DESIGN OF DIFFERENTIAL GEARBOX
CHAPTER 4

Build Geometry

Constructing a 3D representation of
the bevel gears in SOLIDWORKS. The
assembly consists of 2 side gears, 2
ring gears and on sun gear. After
the assembly in SolidWorks. Save the
file in. IGES format continuing the
further work in ANSYS Mechanical.
 ANALYSIS OF DIFFERENTIAL GEAR BOX
CHAPTER 4

Material Properties
Grey Cast Iron

We have used two different

materials like grey cast iron and
aluminum alloy for the analysis of
this product.
 ANALYSIS OF DIFFERENTIAL GEAR BOX
CHAPTER 4

Material Properties
Aluminium

We have used two different

materials like grey cast iron and
aluminum alloy for the analysis of
this product.
 ANALYSIS OF DIFFERENTIAL GEAR BOX
CHAPTER 4

Meshing of Differential Gear Box

In the picture, we can see the fine

meshing on the Aluminium Alloy of
element size of 0.6 and fine meshing
of span angle center. By, meshing
we can do the analysis properly
and perfectly to know the load
values on the differential gear box.
 ANALYSIS OF DIFFERENTIAL GEAR BOX
CHAPTER 4

Torque acting on the Differential

Gear Box

This figure shows the mutual image

of all the available torques applied
on the differential gearbox the
torques applied are 190, 235, 320
(N-m)
 ANALYSIS OF DIFFERENTIAL GEAR BOX
CHAPTER 4

Fixed Support for Differential Gear

Box

In this figure, we are showing the

fixed supports because while
undertaking the structural analysis
we can’t do it without giving the
static supports so we have the fixed
supports to the sun gear hands.
 EXPERIMENTAL RESULTS
CHAPTER 4

Applying Load

It demonstrates the Total

Deformation push estimations of the
differential rigging box at various
torques at 190, 235, 320 (N-m) on
Gray Cast Iron
 EXPERIMENTAL RESULTS
CHAPTER 4

Von-Mises Stress of Differential Gear Box

It demonstrates the Von-Mises pressure

estimations of the differential apparatus
box at various torques at 190, 235, 320 (N-
m) on Gray Cast Iron.
EXPERIMENTAL RESULTS
CHAPTER 4

Total Deformation and Von-Mises Stresses

of Grey Cast Iron
EXPERIMENTAL RESULTS
CHAPTER 4

Total Deformation and Von-Mises Stresses

of Aluminum Alloy
 COST ANALYSIS
CHAPTER 4

To make the differential box, we didn’t have to buy different materials. We used the latest
technology of 3D printing to get the Differential Box Parts. Later on, we painted it and got the
final product.

The Full 3D Printing Costs us 70 OMR and with the painting, 75 OMR Total
 CONCLUSION
CHAPTER 5

In this project, we have taken the frictional contact between the mating gears as 0.2 to see
does the frictional contact the impact the heap or not. From, the above outcomes and
charts we found that both dim cast iron and aluminium composite are best to play out the
use of differential gearbox in vehicles. Be that as it may, with regards to load for light utility
vehicles Aluminium Alloy is favoured.