International Journal of Engineering Technology, Management and Applied Sciences

www.ijetmas.com March 2015, Volume 3 Issue 3, ISSN 2349-4476

Manufacturing of Simple Differential Locking System

Karande Mahesh J.
Uttekar Sudesh N.
Patil Pramod V.
Gawade Atish S.
Department of Mechanical Engineering, Sinhgad Institute of Technology & Science Narhe, Pune,
India
karandemj@gmail.com, sudeshuttekar130@gmail.com, pvpatil1988@gmail.com, atishgawade2929@gmail.com

ABSTRACT
This paper deals with the study and experimentation of differential locking system. Every automobile vehicle running on
road is equipped with the most important part at the rear side called as differential. This is the part which transmits relative
power to both the rear wheels while turning. All gears in differential gearbox have relative motion between them.
Sometimes there is a requirement of transmitting same power to both the wheels when vehicle get stuck into the mud. But
due to relative motion between all gears in the gearbox the stucked wheel rotates at double speed and due to this the vehicle
again gets deeply stucked into the mud. To move the vehicle out from the mud there is requirement of differential locking,
by which both the rear axles are act as a solid shaft. The differential gearbox is one, if we lock any one of the element in
gearbox then whole gearbox will lock and the rear axle shafts will work as a single shaft. To have simple differential
locking system, the different parts used are spike shaft, dog ring and dog moving selector mechanism. The spike shaft is
the shaft situated in between the planet gears. While there is no alteration in the sun gears. In normal running condition the
shaft on which planet gears are mounted is steady. In this locking method one of the planet gear is fixed on one side of
spike shaft, while other gear is free to move. The dog ring is made to slide on the cage of the differential gearbox by
machining the cage surface. Thus the dog ring is able to slide freely on spline on the cage surface. And this dog ring is
moved forward and backward through a dog moving arrangement which consists of a selector mechanism.

Keywords
Differential Locking; Spike Shaft; Dog Ring; Dog Moving Selector Mechanism.

1. INTRODUCTION
When a vehicle comes across a situation of a
slippery road condition or mud, there is
possibility of getting one of the wheel stucked.

Fig. 1 Limited-Slip Differential

171

To bring vehicle out of this condition it

necessary to transmit equal torque to both of
half shafts on either side of the differential, for
this purpose differential locking is required.
There is wide range of differential locking
methods available in current trends of
automobiles. Among these trends LSD is latest
trends available in most of automobiles. LSDs
(Limited Slip differentials) are designed to
"limit" the tendency of open differential to
transmit power to a wheel that lacks traction and
redirect the power to a degree to the other wheel
of the axle. The Limited Slip differential will
send power to both wheels equally when
traveling straight, however when one wheel
spins due to a lack of traction, the differential
will automatically provide torque to the other
wheel with traction. Limited Slip differentials
limit the loss of torque to a slipping wheel

Karande Mahesh J., Uttekar Sudesh N., Patil Pramod V., Gawade Atish S.

International Journal of Engineering Technology, Management and Applied Sciences

www.ijetmas.com March 2015, Volume 3 Issue 3, ISSN 2349-4476

through various types of mechanisms such as

clutches, gears cones, and other methods
dependent on the unit.[6].
Simple differential locking method consists of a
three parts i.e., spike shaft, dog ring and the dog
selector mechanism. And working of this type
of locking system is same as the gear selector
mechanism of the constant mesh gear box.
Working of this type of locking method is
discussed in detail below.

use of differential on an Australian steam car by

David Shearer was done in 1897. Packard
introduces the spiral-gear differential, which
cuts gear noise in the year 1913. Packard
introduced the hypoid differential, which enable
the propeller shaft and its hump in the interior
of the car to be lowered in 1926. Vernon
Gleasman patented the Torsen dual-drive
differential, a type of limited slip differential
that relies solely on the action of gearing instead
of a combination of clutches and gears was
introduced in the year 1958.

2. LITERATURE SURVEY
Concept
Review
There are many claims to the invention of the
differential gear but it is likely that it was
known, at least in some places, in ancient times.
Some historical milestones of the differential
include:
Two Chinese Buddhist monks and engineers
create South Pointing Chariots for Emperor
Tenji of Japan. Documented Chinese
reproductions of the South Pointing Chariot by
Yan Su and then Wu Deren, which described in
detail the mechanical functions and gear ratios
of the device much more so than earlier Chinese
records[14],[15]. Joseph Williamson used a
differential gear in a clock in the year 1720.
Rudolph Ackermann of Germany invented a
four-wheel steering system for carriages, which
some later writers mistakenly reported as a
differential in the year 1810. Modern
automotive differential patented by watchmaker
On Siphore Pecqueur in the period 1792-1852
of the Conservatoire des Arts Et M-tiers in
France for use on a steam carts [16]. Richard
Roberts of England patented 'gear of
Compensation', a differential for road
locomotives in 1832. Aveling and Porter of
Rochester, Kent list a crane locomotive in their
catalogue fitted with their patent differential
gear on the rear axle in the year 1874 [17]. First

172

The six speed constant mesh gear box has two

shafts, one for the input and the other for output.
Six gears are mounted on both the shafts and are
in constant mesh. Ball bearings are connected to
the gears on the output shaft which makes them
to rotate freely on the output shaft. The output
gears have extensions on one side for the
engagement purpose. The clutches are engaged
and disengaged with the gears by the use of
levers.
The clutches are keyed to the output shaft. The
engine flywheel is connected to the input shaft.
The gears on the output shaft rotate freely on
the bearings. In order to engage the dog clutch
with the gear the respective lever is moved. This
moves the clutch towards the gear and the dog
gets engaged with the extensions on the gear.
The rotation is transferred to the output shaft.
The wheels connected to the output shaft are
also rotated.[1], [4].

3. WORKING
Working of this type of locking system is
simple and similar to that of the constant mesh
gear box. Concept of this type of differential

Karande Mahesh J., Uttekar Sudesh N., Patil Pramod V., Gawade Atish S.

International Journal of Engineering Technology, Management and Applied Sciences

www.ijetmas.com March 2015, Volume 3 Issue 3, ISSN 2349-4476

locking system revolves around the concept of

that of the constant mesh gear box shifter
mechanism which consists of the dog ring, dog
clutch, dog teeth and the gear which is to be
engaged. Here the only difference is that instead
of the gear to engaged, the dog teeth on dog ring
is engaged into the teeth on the spike shaft. The
spike shaft is the shaft on which planet gears are
mounted. The shaft on which the planet gears
are mounted is always stationary allowing the
planet free to rotate on it.[2], [3], [5], [9], [11].
But, this shaft is made to have spikes on one
side and has one planet gear fixed on one side.
The spike shaft rotates around itself as well as
the rotates at the axis of rotation of the cage.
The dog ring is a circular ring shaped
component
on
which
a
teeth
is
welded/fabricated for the purpose of
engagement of the dog ring with the spike shaft.

gear box is same as that of the movement of the

dog ring installed on the constant mesh gear
box. For working of the locking system
following elements are required for the
purpose of locking i.e., spike shaft, dog ring
and
dog moving selector mechanism. The
dog ring is provided with a single dog teeth for
engagement. Shifter mechanism moves the dog
ring toward left and the dog teeth engages in to
the spike shaft teeth. Presently the dog ring is
provided with a single teeth for engagement [7].

Fig. 3 Constant mesh gear box

Fig. 2 Experimental Setup

Dog clutch is the component which rests on the

dog ring and makes the dog ring to slide on the
cage in forward and backward direction. The
working of the dog clutch in any constant mesh
gear box is to make the dog ring slide and
engage its teeth into the desired gear teeth.
Thus, making the desired gear to be engaged as
per wish of the driver of the vehicle. Spike shaft
is provided with teeth on the top of it.
Engagement will lock the spike shaft thereby
the conventional differential actions stops and
both the wheel shafts get engaged in drive and
thus equal power is given to either wheels.
Wheel shafts are required for the purpose of
transmitting motion from the sun gear to the
wheels.

The dog ring is as shown in the figure 5. The

movement of the dog ring in the differential

173

Karande Mahesh J., Uttekar Sudesh N., Patil Pramod V., Gawade Atish S.

International Journal of Engineering Technology, Management and Applied Sciences

www.ijetmas.com March 2015, Volume 3 Issue 3, ISSN 2349-4476

... (2)

4.DESIGN OF LOCKING
ELEMENTS

&

Considering the basic locking elements in this

type of locking system, design of these elements
was on the basis of the capability of the material
to provide the differential locking system with a
good service life, economical considerations as
well as availability of the material.[10]. The
elements considered for design are as follows.
[13]

... (3)
Selected whichever is minimum.
B. Input torque
... (4)

Spike Shaft
The spike shaft is the shaft on which planet
gears are mounted. The shaft on which the
planet gears are mounted is always stationary
allowing the planet free to rotate on it. But, this
shaft is made to have spikes on one side and has
one planet gear fixed on one side. The spike
shaft rotates around itself as well as the rotates
at the axis of rotation of the cage.

... (5)

Dog Ring
The dog ring is a circular ring shaped
component on which a teeth is welded/
fabricated for the purpose of engagement of the
dog ring with the spike shaft. The dog ring is as
shown in the figure. The movement of the dog
ring in the differential gear box is same as that
of the movement of the dog ring installed on the
constant mesh gear box.
Parameter selected for design of dog ring is Dog
teeth.
C. Tangential force on teeth (F) -

Fig. 4 Spike Shaft

A. Shear failure of shaft-

... (1)

Maximum shear stress theory for the failure of

the shaft.

D. Shear stress in dog teeth

... (1)
Permissible value of shear stress
According to ASME code

174

Karande Mahesh J., Uttekar Sudesh N., Patil Pramod V., Gawade Atish S.

... (2)

International Journal of Engineering Technology, Management and Applied Sciences

www.ijetmas.com March 2015, Volume 3 Issue 3, ISSN 2349-4476

E. Input Torque.
... (3)
Assuming 100% overload.
... (4)

F. Torsional Shear Failure of Shaft.

... (5)
Fig. 5 Dog ring

Output Shaft
Output shaft is shaft which is used to transmit
the power from the sun gear to the wheels.

Fig. 6 Output Shaft

Using ASME code for design of shaft
... (1)
OR
... (2)
Considering minimum of the above values.

Shaft is provided with key way; this will reduce

its strength. Hence reducing above value of
allowable stress by 25%. This is the allowable
value of shear stress that can be induced in the
shaft material for safe operation.

175

5. NOMENCLATURE
Symbol Quantity
Unit
T
Torque/ Twisting
N-mm
moment,
Design Torque/ Twisting N-mm
moment,
d
diameter of the shaft,
mm
Shear Stress in the
N/mm2
elements,
Maximum Shear Stress in N/mm2
the elements,
Actual Shear Stress in the N/mm2
elements,
F
Tangential force,
N
Dp
PCD of dog ring,
mm
n
Number of teeth,
P
Power transmitted by the kW
motor,
Ultimate tensile strength, N/mm2
Yield strength,
N/mm2
N
Speed of the motor ,
rpm
Table 1. Nomenclature of the design elements

Karande Mahesh J., Uttekar Sudesh N., Patil Pramod V., Gawade Atish S.

International Journal of Engineering Technology, Management and Applied Sciences

www.ijetmas.com March 2015, Volume 3 Issue 3, ISSN 2349-4476

6. MATERIAL SELECTION
EN24 is usually supplied in the T condition
with a tensile strength of 800-1000 N/mm2.
EN24T steel is a popular grade of throughhardening alloy steel due to its excellent
machinability in the "T" condition. EN24T is
used in components such as gears, shafts, studs
and bolts, its hardness is in the range 248-302
HB. EN24T can be further surface-hardened to
create components with enhanced wear
resistance by induction or nitriding processing.
Designation

Ultimate Tensile Yield Strength

Strength
N/mm2
N/mm2
EN 24
800
680
Table 2. Selection of material

7. EXPERIMENTATION &
RESULTS
Experimentation
For the purpose of experimentation the
assembly of the differential gear box was
installed on a frame equipped with a
dynamometer arrangement as shown in the
figure. The experimentation was done in a
following way.
Firstly, the assembly was made with arranging
properly the casing of the differential gear box
on the frame. Providing this assembly with the
dog moving arrangement for the purpose of
locking the differential gear box. And the
required electrical circuitry was made. Readings
were taken for the variation in speed of the
either shafts without and with the engagement
of the locking system. The procedure for
carrying out the experimentation is as follows.
Secondly, make the proper electrical
connections and run the prime mover i.e.,

176

motor. This motor is connected to the

differential gear box as source of power to be
transmitted to the input shaft. This input shaft
runs the output shaft through the respective
gears assembly.

Results
1) Without the engagement of the locking
assembly the speeds at the respective shafts
were found out.
The results tabulated below
Sr. Motor
No. Speed
rpm

Input
Shaft
Speed
rpm

Load
Kg

Output Shaft
Speed rpm
Left
Right
Side
Side
Shaft Shaft
395
395

6500

1600

6100

1520

263

440

5600

1480

198

485

5300

1360

132

530

4900

1230

66

575

4600

1160

598

Table 3. Result Table - Variation in shaft speeds

without the engagement of the locking assembly
From the above observation table it is clear that
on applying increasing load on the left side shaft
there is decrease in speed of the left side shaft
and increase in the speed of the right side shaft.
This shows the working of conventional
differential.
2) With the engagement of the locking assembly
the speeds at the respective shafts were found
out.

Karande Mahesh J., Uttekar Sudesh N., Patil Pramod V., Gawade Atish S.

International Journal of Engineering Technology, Management and Applied Sciences

www.ijetmas.com March 2015, Volume 3 Issue 3, ISSN 2349-4476

Motor
Sr. Speed
No. rpm

Input
Shaft Load
Speed Kg
rpm

6500

1600

Output Shaft
Speed rpm
Left
Right
Side
Side
Shaft Shaft
395
395

5600

1120

280

280

4000

840

220

220

Table 4. Result Table - Variation in shaft speeds

with the engagement of the locking assembly
From the observation table it is clear that as
load increases the speed of motor will decreases
and above the capacity of motor the motor will
come to stand still because of limited load
carrying capacity of the motor.

Load Vs Speed

Speed 'rpm'

800
600
200
0
0

2
3
Load 'Kg'

Fig. 7 Graph of Load Vs Speed without

differential locking
The results obtained without locking are plotted
in the graphical form. The graph shows speed of
left side and right side shafts Vs load without
differential locking. From graph it is clear that
both the shafts have variation in speed due to
application of load on left side shaft.

177

Load Vs Speed

500
400
300
200
100
0

LH Shaft
Speed
0

1
Load 'Kg'

RH Shaft
Speed

Fig. 8 Graph of Load Vs Speed without

differential locking
The results obtained from the method of locking
are plotted in the graphical form. The graph
shows speeds of left side and right side shafts
Vs load with differential locking. From graph it
is clear that both the shafts have same speed due
to differential locking. Hence, the graph
obtained is superimposed.

8. CONCLUSION
LH
Shaft
Spee
d

400

Speed 'rpm'

The results tabulated below

The results obtained from with and without

locking the differential convey the limitations of
conventional differential and a better option for
the conventional users to go for this convenient
method of differential locking. Results obtained
from the experimentation predict the effective
locking which is required by the differential
when the vehicle wheel stucked in to any
obstacle like mud.

Acknowledgment
We are thankful to our Project Guide
Prof. B. D. Patil Sir and faculty of Department
of Mechanical Engineering, Sinhgad Institute
of Technology & Science, Narhe, Pune for
giving this opportunity to enhance our project
study.

Karande Mahesh J., Uttekar Sudesh N., Patil Pramod V., Gawade Atish S.

International Journal of Engineering Technology, Management and Applied Sciences

www.ijetmas.com March 2015, Volume 3 Issue 3, ISSN 2349-4476

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Karande Mahesh J., Uttekar Sudesh N., Patil Pramod V., Gawade Atish S.