DESIGN AND ANALYSIS OF DIFFERENTIAL GEAR BOX IN AUTOMOBILES

International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 5, May 2017, pp. 175 185 Article ID: IJMET_08_05_019 Available online at http:// http://www.iaeme.com/ijmet/issues.asp?jtype=ijmet&vtype=8&itype=5 ISSN Print: 0976-6340 and ISSN Online: 0976-6359 IAEME Publication Scopus Indexed DESIGN AND ANALYSIS OF DIFFERENTIAL GEAR BOX IN AUTOMOBILES N. Siva Teja Asst. Professor, Dept. of Mechanical Engineering, K L University, Vaddeswaram, Andhra Pradesh K. Dinesh Babu, M. Siva Nagendra, Ch. Phanideep, J. Sai Trinadh Dept. of Mechanical Engineering, K L University, Vaddeswaram, Andhra Pradesh, ABSTRACT The main objective of this paper is to perform mechanical design of differential gear box and analysis of gears in gear box. We have taken grey cast iron and aluminium alloy materials for conducting the analysis. Presently used materials for gears and gears shafts is Cast Iron, Cast Steel. So, in this paper 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. Key words: Differential Gear Box, Structural Analysis, Design and Structural Analysis of Differential Gear Box Cite this Article: N. Siva Teja, K. Dinesh Babu, M. Siva Nagendra, Ch. Phanideep, J. Sai Trinadh, Design and Analysis of Differential Gear Box In Automobiles, International Journal of Mechanical Engineering and Technology, 8(5), 2017, pp. 175-185. http:// http://www.iaeme.com/ijmet/issues.asp?jtype=ijmet&vtype=8&itype=5 1. INTRODUCTION A differential is a gear train with three shafts that has the property that the angular velocity of one shaft is the average of the angular velocities of the others, or a fixed multiple of that average. A gear box provides speed and torque conversions from a rotating power source to another device using gear ratios. In automobiles and other wheeled vehicles, the differential allows the outer drive wheel to rotate faster than the inner drive wheel during a turn. This is necessary when the vehicle turns, making the wheel that is traveling around the outside of the turning curve roll farther and faster than the other. The average of the rotational speed of the two driving wheels equals the input rotational speed of the drive shaft. An increase in the speed of one wheel is balanced by a decrease in the speed of the other. When used in this way, a differential couples the input shaft (or prop shaft) to the pinion, which in turn runs on the ring gear of the differential. This also works as http://www.iaeme.com/ijmet/index.asp 175 editor@iaeme.com

Design and Analysis of Differential Gear Box In Automobiles reduction gearing. On rear wheel drive vehicles, the differential may connect to half-shafts inside an axle housing, or drive shafts that connect to the rear driving wheels. Front wheel drive vehicles tend to have the pinion on the end of the main-shaft of the gearbox and the differential is enclosed in the same housing as the gearbox. There are individual drive-shafts to each wheel. 2. OBJECTIVES OF PRESENT WORK We are creating the frictional contact between two mating gears. And we are doing the structural analysis on gear box by providing the torque to the sun gear in the differential gear box. 3. MODELING AND ANALYSIS 3.1. Modeling details To determine the structural analysis on the differential gear box. First, we have to create a model of differential gear box in modeling software s. We have the assembly of differential gear box in SOLIDWORKS. 3.2. Build Geometry Construct a three-dimensional representation of the bevel gears in SOLIDWORKS. The assembly consists of 2 side gears, 2 ring gears and on sun gear. After doing the assembly in solidworks. Save the file in. IGES format continuing the further work in ANSYS Mechanical. Figure 3.1.1 FinalAssembly of differential gear box http://www.iaeme.com/ijmet/index.asp 176 editor@iaeme.com

N. Siva Teja, K. Dinesh Babu, M. Siva Nagendra, Ch. Phanideep, J. Sai Trinadh 4. DESIGN OF DIFFERENTIAL GEAR BOX Figure 4.1.1 This figure represents the modeling of first side gear in solidworks. It is creaeted by drawing the bevel gear profile from prerequisites and removing the faces of bevel gear tooth for 45 deg mating of other gears for assembly.and adding an extruded stub axles rods to it. Figure 4.1.2 It is the second bevel side gear.this figure represents the modeling of second side gear in solidworks. It is creaeted by drawing the bevel gear profile from prerequisites and removing the faces of bevel gear tooth for 45 deg mating of other gears for assembly.and adding an extrude stub axles to it. Figure 4.1.3 This figure represents the modeling of ring gear in solidworks. It is creaeted by drawing the bevel gear profile from prerequisites and removing the faces of bevel gear tooth for 45 deg mating of other gears for assembly.and adding an xtrude stub axles to it. The ring rotates while the vehicle is taking a turn. It rotates in it s own axis. http://www.iaeme.com/ijmet/index.asp 177 editor@iaeme.com

Design and Analysis of Differential Gear Box In Automobiles Figure 4.1.4 This figure represents the modeling of sun gear in solidworks. It is creaeted by drawing the bevel gear profile from prerequisites and removing the faces of bevel gear tooth for 45 deg mating of other gears for assembly.and adding an extruded sun gear plates for the fixing of two side and two ring gears.the sun gears carry the torque that is coming from the engine. 5. ANALYSIS OF DIFFERENTIAL GEAR BOX 5.1. Engineering Data We have used two different materials like grey cast iron and aluminium alloy for the analysis of this product. Table:5.1.1 It Shows The Material Properties of grey cast iron. Density Coefficient of Thermal Expansion 7200 kg m^-3 1.1e-005 C^-1 Specific Heat 447 J kg^-1 C^-1 Thermal Conductivity 52 W m^-1 C^-1 Resistivity 9.6e-008-ohm m Young's Modulus Pa 1.1e+011 Poisson's Ratio 0.28 Tensile Ultimate Strength 2.4e+008 Compressive Ultimate Strength 8.2e+008 Table 5.1.2: It Shows The Material Properties of Aluminium Alloy. Density 2770 kg m^-3 Coefficient of Thermal Expansion 2.3e-005 C^-1 Specific Heat 875 J kg^-1 C^-1 Young's Modulus Pa 7.1e+010 Poisson's Ratio 0.33 Resistivity 3.63e-008-ohm m Thermal Conductivity 114 W m^-1 C^-1 Tensile Yield Strength 2.8e+008 Tensile Ultimate Strength 3.1e+008 http://www.iaeme.com/ijmet/index.asp 178 editor@iaeme.com

N. Siva Teja, K. Dinesh Babu, M. Siva Nagendra, Ch. Phanideep, J. Sai Trinadh 5.2. Frictional Contacts Figure 5.2.1 It shows the frictional coefficient between the mating gears as 0.2. for the frictional or rubbing contact between to test for the thermal conditions. 5.3. Meshing of Differential Gear Box Figure 5.3.1 In this figure, I am representing the fine meshing on the grey cast iron 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. Figure 5.3.2 In this figure, I am representing 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. http://www.iaeme.com/ijmet/index.asp 179 editor@iaeme.com

Design and Analysis of Differential Gear Box In Automobiles 5.4. Torque acting on the Differential Gear Box Figure 5.4.1 This figure shows the combined image of all torques applied on the differential gear box the torques applied are 190, 235, 320 (N-m). 5.5. Fixed Support for Differential Gear Box Figure 5.5.1: In this figure, we are representing the fixed supports because while doing the structural analysis we can t do it without giving the fixed supports so we have the fixed supports to the sun gear hands because it doesn t imply any forces on the analysis of the paper. http://www.iaeme.com/ijmet/index.asp 180 editor@iaeme.com

N. Siva Teja, K. Dinesh Babu, M. Siva Nagendra, Ch. Phanideep, J. Sai Trinadh 6. EXPERIMENTAL RESULTS of Grey Cast Iron Figure 6.1 It shows the stress values of the differential gear box at different torques at 190, 235, 320 (N-m) on Grey Cast Iron Von-Mises Stress of Differential Gear Box: Figure 6.2 It shows the Von-Mises stress values of the differential gear box at different torques at 190, 235, 320 (N-m) on Grey Cast Iron. http://www.iaeme.com/ijmet/index.asp 181 editor@iaeme.com

Design and Analysis of Differential Gear Box In Automobiles of Aluminium Alloy Figure 6.3 It shows the stress values of the differential gear box at different torques at 190, 235, 320 (N-m) on Aluminium Alloy. Von-Mises Stress of Differential Gear Box Figure 6.4 It shows the Von-Mises stress values of the differential gear box at different torques at 190, 235, 320 (N-m) on Aluminium Alloy. http://www.iaeme.com/ijmet/index.asp 182 editor@iaeme.com

N. Siva Teja, K. Dinesh Babu, M. Siva Nagendra, Ch. Phanideep, J. Sai Trinadh 7. RESULTS & DISCUSSIONS 7.1. and Von-Mises Stresses of Grey Cast Iron S.no Torque (N-m) (mm) Von-Mises Stresses (MPa) 1 190 2.6424*e^-3 20.6847 2 235 2.6415*e^-3 32.681 3 320 2.6399*e^-3 43.716 7.2. and Von-Mises Stresses of Aluminium Alloy Graphs S.no For Grey Cast Iron Torque (N-m) (mm) Von-Mises Stresses (MPa) 1 190 1.5791*e^-3 25.029 2 235 1.578*e^-3 30.773 3 320 1.646*e^-3 44.18 Von-Mises Stress 45 40 35 30 25 190 235 320 Von-Mises Stress 0.002641 0.002639 0.002637 0.002635 190 235 320 http://www.iaeme.com/ijmet/index.asp 183 editor@iaeme.com

Design and Analysis of Differential Gear Box In Automobiles For Aluminium Alloy Von-Mises Stress 60 40 20 0 190 235 320 Von-Mises Stress 0.0017 0.00165 0.0016 0.00155 0.0015 190 235 320 7. CONCLUSION In this project, we have taken the frictional contact between the mating gears as 0.2 to see does the frictional contact the effect the load or not. From, the above results and graphs we found that both grey cast iron and aluminium alloy are preferable for performing the application of differential gearbox in automobiles. But, when it comes to weight for light utility vehicles Aluminium Alloy is preferred. REFERENCES [1] N. Vijay Babu, Ch. Sekhar, Design and Analysis of Differential Gear Box Used In Heavy Vehicles, ishitv, 20-21 nov, 2015. Vol.2, No.1. [2] C. Veeranjaneyulu, U. Hari Babu, Design and Structural Analysis of Differential gear Box At Different Loads, ijaer, 2002, ongole, Andhra Pradesh. [3] Sumair Sunny, Siddhesh Ozarkar, Sunny Pawar, Design of An Automotive Differential With Reduction Ratio Greater Than 6, IJRET, 2006. [4] S.H. Gawande, S.V. Khandagale, V.T. Jadhav, V.D. Patil, D.J. Thorat, Design, Manufacturing And Analysis Of Differential Crown Gear and Pinion For MFWD Axle, IOSR, Pune India [5] R. Morselli, Detailed and Reduced Models of Passive and Active Limited Slip Car Differentials, August 2006. [6] G.M. Mitra, Hand Book of Gear Design, Tata McGraw Hill, New Delhi. [7] Daniel Das.A, Seenivasan.S, Karthick.S, Structural Analysis of Gear Ox, JIET, April 2013, Vol.2 issue 2. [8] J.O. Nordiana, S.O. Ogbeide, N.N. Ehigiamusoe and F.I. Anyasi, Computer Aided Design of A Spur Gear, Journal of Engineering and Applied Sciences, 2003. http://www.iaeme.com/ijmet/index.asp 184 editor@iaeme.com

N. Siva Teja, K. Dinesh Babu, M. Siva Nagendra, Ch. Phanideep, J. Sai Trinadh [9] Zeping Wei, Stresses and Deformations in Involute Spur Gears by Finite element Method, M.S, Thesis, College of Graduate Studies and research, University of Saskatchewan, 2004. [10] K. Sunil Kumar, Dr. Sumathy Muniamuthu, S. Arun and A. Mohan, Identification Experimental Analysis of Noise and Vibration Reduction in Windmill Gear Box for 5MW Wind Turbine. International Journal of Mechanical Engineering and Technology, 7(6), 2016, pp. 76 85. [11] P.Vinay, Ch. Venkata Satya Sri Vamsi, M.Hemanth, A.Saiteja, Mohammad Abid Ali and P. Ashok Kumar, Design and Simulation of Mems Based Accelerometer For Crash Detection and Air Bags Deployment In Automobiles, International Journal of Mechanical Engineering and Technology, 8(4), 2017, pp. 424-434 [12] Darle W. Dudley, Hand Book of Practial Gear Design, 1954. [13] Alce Strokes, High Performance of Gear Design, 1970. http://www.iaeme.com/ijmet/index.asp 185 editor@iaeme.com