Modeling and Structural Analysis of Rear End Differential Gear Box at Different Speeds with Different Materials

Abstract

The main aim of this project work is to perform mechanical design & structural analysis of differential gear box. This is necessary when the vehicle turns. The Differential gear is a part for all four wheeler, wheel reserved the power from engine to gear box then by drive shaft to differential gear. A differential is a gear train that transmits an engine's torque to the wheels. During a turn, the outer and inner wheels of the vehicle are forced to travel along paths of different radii. A differential allows the outer driving wheel to rotate at a faster speed when compared to the inner driving wheel during a turn. The analysis is conducted to verify the best material for the gears in the gear box at higher speeds by analyzing stress, strain, total deformation and also by considering weight reduction. Generally, materials used for gears and gear shafts are Cast Iron, magnesium alloy, Cast steel. This project is testing different materials like Aluminum alloy material for reducing the weight of the differential gear box. In this work the differential gear box is designed with Catia V5R20 software. The complete design is imported to ANSYS 14.5 software and analyzed. This analysis is conducted to know the best material for gears in the gearbox at high speed. We consider the factors like stress, strain, total deformation. When comparing the stress, strain total deformation values of the three materials like cast steel, aluminum alloy, magnesium alloy for different speeds at 2400 rpm, 4400 and 115N-m torque. By observing analysis the Result will be displayed and compared to find the most suitable design