MANSUR RAJ

13N71D0408
DRK INSTITUTE OF SCIENCE
&
TECHNOLOGY
ASSEMBLY ANALYSIS OF
GEARTRAIN IN DIFFERENTIAL
ABSTRACT

Differential is used when a vehicle takes a turn, the outer wheel on a longer
radius than the inner wheel. The outer wheel turns faster than the inner wheel that is
when there is a relative movement between the two rear wheels. If the two rear wheels
are rigidly fixed to a rear axle the inner wheel will slip which cause rapid tire wear,
steering difficulties and poor load holding.

Differential is a part of inner axle housing assembly, which includes the differential
rear axles, wheels and bearings. The differential consists of a system of gears arranged
in such a way that connects the propeller shaft with the rear axles.

The following components consists the differential:

a) Crown wheel and pinion. b) Sun gears c) Differential
casing

The main aim of the project is to focus on the mechanical design and contact
analysis on assembly of gears in gear box when they transmit power at different speeds
at 2400 rpm and 6400 rpm. Analysis is also conducted by varying the materials for
gears, Cast Steels and Aluminum Alloy.
The analysis is conducted to verify the better material for the gears in the gear box
at higher speeds by analyzing stress, displacement and also by considering weight
reduction.

INDEX
1) Differential gear box

2) Calculations

3) Assembly

4) Analysis

5) Comparison of results
DIFFERENTIAL GEAR BOX
Function:-
i) Transmit motion from engine shaft
to rear wheels.
ii) Maintain different speeds of rear
wheels while turning .
Components :-
1) Crown Wheel
2) Sun Gear
3) Casing
TANGENTIAL LOAD (Wt)
W
T
= (
O
x C
v
).b.. m. y
1
P(
(L-b)/L)
C
v
= velocity factor =3/3+v
V= peripheral speed in m/s=
b=For satisfactory operation of the bevel gears the face width
should be from 6.3m to 9.5m
So b is taken as 9.5m
m= module
y
1
p= tooth form factor = 0.154-0.912/ T
E

L= slant height of pitch cone
D
G
= pitch diameter of gear
D
p
= pitch diameter of gear

O
=allowable static stress =
u
/3
DESIGN CALCULATIONS OF
DIFFERENTIAL
DYNAMIC LOAD (W
D
)

W
D
= W
T
+ W
I

W
D =
W
T
+

V = pitch line velocity
B = face width
C = dynamic factor in N/mm=

K = 0.111 for 20 full depth involute system
E
P
= youngs modulus for material of pinion in N/mm
2

E
G
= youngs modulus for material of gear in N/mm
2

e = tooth error action in mm (value for module=10 used in
precision gears is e=0.023)


SPECIFICATIONS OF ASHOK LEYLAND

Maximum power= 162 bhp
Bevel gearing arrangement =90
Diameter of crown wheel = D
G
= 475mm
Number of teeth on gear = T
G
=50
Number of teeth on pinion = T
P
= 8
Module = m=D
G
/T
G
=475/50=9.5=10
Diameter of pinion =m x T
P
=10x8=80mm
Brinell hardness number Ni.cr alloy(BHN)=444
Brinell hardness number Al alloy(BHN)=140

u
=ultimate tensile strength(Ni.cr)=380 Mpa

u
=ultimate tensile strength(Al alloy)=517
Mpa


ASSEMBLY
INTRODUCTION TO CAD (PRO-E)
CAD is used in the design of tools and
machinery and in the drafting and design of all
types of buildings, from small residential types
(houses) to the largest commercial and industrial
structures .

PRO-E
It is a parametric & feature based
software, for developing of Design
structures.
MODEL OF DIFFERENTIAL GEAR

ASSEMBLY OF A MODEL
ANALYSIS
INTRODUCTION TO FEA
Finite element method was initially developed for
the analysis of different structures.

DISCRETIZATION
The process of subdividing a problem entity Into
smaller section called as discretization

The next step after discretization is meshing of a
structure with respect to provided data

ANSYS
ANSYS is analysis part of 3d modeling software.

Three basic steps involved in analysis are
i)Pre-processor [input like material properties load ,
meshing etc.]

ii)Solution [solving]

iii)Post-processor [output & results]


PROCESS OF ANALYSIS IN ANSYS
STRUCTURAL ANALYSIS
i) Applying material properties
ii) Fixed geometry
iii)Applying loads
iv) Meshing
v) Solving
vi) Results
MATERIAL PROPERTIES
NAME OF THE
MATERIAL
Nickel Chrome Steel Aluminum alloy
YIELD STRENGTH
1.72339e+008 N/m^2 1.65e+008 N/m^2
Elastic modulus: 2e+011 N/m^2
7e+010 N/m^2

Poisson's ratio
0.28 0.33
Mass density
7800 kg/m^3 2600 kg/m^3
Shear 7.7e+010 N/m^2
3.189e+008 N/m^2
Stress
2.29414 N/mm^2
3.19018 N/mm^2
Fixed geometry Applying loads
Meshing
STUDY RESULTS OF ALUMINUM
ALLOY
Stress Displacement
Strain
6400 RPM
RESULTS TABLE
Ni Cr Alloy Steel Aluminum Alloy
TANGENTIAL LOAD (N) 2093.8 2922.51
DISPLACEMENT (mm) 0.00615413 0.0241696
STRESS (N/mm
2
) 2.29414 3.19018
STRAIN 1.0400e
-5
4.1593e
-5

STATIC LOAD (N) 56141.9 18143.3
DISPLACEMENT (mm) 0.164988 0.150063
STRESS (N/mm
2
) 63.5052 19.8068
STRAIN 0.000280882 0.000258239
2400 RPM
6400 R P M Ni Cr Alloy Steel Aluminum Alloy
TANGENTIAL LOAD (N) 915.177 1276.18
DISPLACEMENT (mm) 0.00268949 0.0105555
STRESS (N/mm
2
) 1.03521 1.36296
STRAIN 4.57869e
-6
1.80467e
-5

STATIC LOAD (N) 56141.9 18143.3
DISPLACEMENT (mm) 0.164873 0.11763
STRESS (N/mm
2
) 61.8853 19.3772
STRAIN 0.000290205 0.000256567
CONCLUSION
In our project we have designed a differential gear box for Ashok
Leyland 2516M. Loads are calculated when the gears are transmitting
different speeds 2400rpm and 6400 rpm and different materials Alloy Steel,
Aluminum Alloy.
Structural analysis is done on the differential gear box to verify the
best material by taking in to account stresses, displacements, weight etc.
By observing the structural analysis results using Aluminum alloy the
stress values are within the permissible stress value. So using Aluminum
Alloy is safe for differential gear. When comparing the stress values of the
two materials for all speeds 2400rpm and 6400 rpm, the values are less for
Aluminum alloy than Alloy Steel.
And also weight of the Aluminum alloy reduces almost 3 times when
compared with Alloy Steel since its density is very less. Thereby mechanical
efficiency will be increased.
By observing analysis results, Aluminum Alloy is best material for
Differential.
T H A N K Y O U
Q U E R I E S