Abstract
With the continuous development of the automotive industry and the rising level of the country’s economy, there are increasing demands for vehicles’ safety, economy, comfort, and durability. Therefore, it is important to take vehicles’ mass reduction and product life into consideration. Among the most popular factors: lightweight design, structural optimization, and analysis based on software are important and become growing mature in studies and research. Most scholars have focused their research on the vehicle drive system, with very few specializing in the structure and performance of the differential component. This paper will focus on and unify structural design, lightweight design of a differential case, Ansys finite element method (FEM) analysis of stress, fatigue, and distortion, and optimization to obtain a safe structure with less mass. Initially, construct a geometrical model of the differential case using 3D modelling via SolidWorks software. In addition, mechanical performance analysis of the differential case under three operating occasions is conducted based on Ansys software. Meanwhile, exploring the material selection and shape design methods. Ultimately, the results are justified, and gaining aluminium has longer life. QT450-10 ductile iron has better safety factors, strength, and stiffness. Lightweight design and analysis are realized supporting further research.
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