OPTIMIZATION OF GEARBOX WITH

INTEGRATED OPEN DIFFERENTIAL

UNIT

A PROJECT REPORT

Submitted by

SANJAY R - 412519114124
SIVASANKAR K - 412519114136
PREMKUMAR K - 412519114308

in partial fulfilment for the award of the degree of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

SRI SAI RAM ENGINEERING COLLEGE

(An Autonomous Institution; Affiliated to Anna University,
Chennai -600 044)

ANNA UNIVERSITY: CHENNAI 600 025

APRIL 2023

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 ANNA UNIVERSITY, CHENNAI – 600 025

BONAFIDE CERTIFICATE

Certified that this project report “Optimization of Gearbox with

Integrated Open Differential Unit” is the bonafide work of
SANJAY R - 412519114124
SIVASANKAR K - 412519114136
PREMKUMAR K - 412519114308
who carried out the project work under my supervision.

SIGNATURE SIGNATURE
Dr. B. VIJAYA RAMNATH, Dr. C. PARSWAJINAN,
HEAD OF THE DEPARTMENT, SUPERVISOR,
Professor, Associate Professor,
Department of Mechanical Engineering, Department of Mechanical Engineering,
Sri Sai Ram Engineering College, Sri Sai Ram Engineering College,
Chennai- 600 044. Chennai- 600 044.

Submitted for University Project Viva-Voce Examination held on

........................…………. at Sri Sai Ram Engineering College, Chennai-600 044.

INTERNAL EXAMINER EXTERNAL EXAMINER

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 ACKNOWLEDGEMENT

With the blessings of our beloved Founder Chairman Shri. MJF. Ln. LEO MUTHU, we have
successfully completed our project.

We are extremely grateful to our CEO & Chairman Dr. SAI PRAKASH LEO MUTHU, for
providing us with the opportunity to pursue our project and for his continuous support and
guidance throughout the project.

We extend our heartfelt gratitude to our Principal Dr. K. PORKUMARAN, and Dean
Dr. A. RAJENDRA PRASAD, for their constant support, encouragement, and guidance
towards the completion of this project.

We wish to express our gratefulness and gratitude to our beloved Head of the Department –
Mechanical Engineering Dr. B. VIJAYA RAMNATH, Professor, for his encouragement,
support and guidance.

We are deeply indebted to our Project guide Dr. C. PARSWAJINAN, Associate Professor,
Department of Mechanical Engineering for his intellectual guidance, technical assistance, and
feedback during the project. His support has been crucial in completing our project successfully.

We also thank our project coordinator Dr. N. VASUDEVAN, Associate Professor, Department
of Mechanical Engineering and Mr. S. RAMANATHAN, Assistant Professor, Department of
Mechanical Engineering for their unceasing ideas, which helped us to take the right decision to
attain our goals.

We express our sincere thanks to our faculty member, Dr. S. VAIDYANATHAN, Professor,
Department of Mechanical Engineering for his assistance throughout the course of our project.

We also express our sincere gratitude to all the Teaching and non- teaching faculty members of
our Department of Mechanical Engineering who contributed directly or indirectly in our project.

We are grateful to our parents unwavering support and inspiration throughout this project.
Without their guidance and inspiration, this project would not have gone ahead.

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 ABSTRACT

The transmission system multiplies the torque of the engine so that the
power peak is reached at its full potential. A differential is a gear train that
transmits an engine's torque to the wheels. The gears in the differential are
supported by a cage which results in its bulky appearance and heavy form. This
causes many disadvantages such as differences in the length of the driveshafts and
offsets center of mass of the system due to asymmetrical design. Such a cage also
adds additional weight to the vehicle and increases the price and fuel consumption
as a consequence. Also in automobile vehicles, the gearbox and differential are
used as individual components. Its removal outcomes in a greater compact and
light-weight configuration. This research focuses on the complete analysis of the
optimization of a gearbox with an Integrated open differential unit. Various
substances were considered for the assembly and one with adequate properties of
energy, put on resistance, and different core parameters had been selected. Gear
ratios were obtained through theoretical calculation and the values were used as
input for designing. Finite element analysis of the gear train was carried out to test
the structural integrity and durability of the system through various types of
analysis such as linear static structural, fatigue, and explicit dynamic analysis. The
results proved that the design meets the desired features and is an improvement
over the traditional type of differential gearbox.

Key words: ATV, Gearbox, 2 stage reduction, Differential, Spur gear, Torque,
Speed.

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 TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

ABSTRACT iv
LIST OF FIGURES viii
LIST OF TABLES x
LIST OF NOMENCLATURE xi

1. INTRODUCTION 01
1.1 INTRODUCTION OF DIFFERENTIAL 01
1.2 WHAT IS GEAR BOX? 02
1.3 WHAT IS DIFFERENTIAL? 02
1.4 WHY GEARBOX & DIFFERENTIAL IS NEEDED 03
1.5 HOW GEARBOX WITH INTEGRATED OPEN
DIFFERENTIAL UNIT WORKS 03
1.5.1 WHEN THE VEHICLE MOVES STRAIGHT 04
1.5.2 WHEN THE VEHICLE TAKING A TUNG 04
1.6 TYPES OF DIFFERENTIALS 04
1.6.1 OPEN DIFFERENTIAL 05
1.7 CAGELESS DIFFERENTIAL 06
1.8 SUMMARY 07
2. LITERATURE REVIEW 08
2.1 LITERATURE SURVEY 08
2.2 SUMMARY OF LITERATURE SURVEY 14
2.3 IDENTIFICATION OF RESEARCH GAP 15
2.4 SUMMARY 15
3 METHODOLOGY 16
3.1 GRAPHICAL ABSTRACT 16
3.2 METHODOLOGY FLOW CHART 17
3.3 SUMMARY 18

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4 MATERIAL SELECTION 19
4.1. FACTORS OF MATERIAL OF SELECTION 19
4.1.1 GEARS 19
4.1.2 CASING 21
4.1.3 BUSHES 22
4.2. HEAT TREATMENT PROCESSES 23
4.2.1. ANNEALING 23
4.2.2. HARDENING 23
4.2.3. CARBURIZING 23
4.2.4. NITRIDING 24
4.2.5. QUENCHING 24
4.2.6. TEMPERING 24
4.3. COMPARISON 24
4.4. SUMMARY 26
5 DESIGN CALCULATIONS 27
5.1 FIXED PARAMETERS 27
5.2 TRACTION CALCULATION 27
5.3. GEAR DIMENSION CALCULATION 31
5.4 GEAR RATIO CALCULATION 33
5.5 FORCE CALCULATION 34
5.6 STRESS CALCULATION 36
5.7 INDUCED STRESS CALCULATION 37
5.8 SUMMARY 39
6 DESIGN 0F 2D DRAFTING AND 3D MODELING 40
6.1 DESIGN OF 2D DRAFTING 40
6.2 DESIGN OF 2D LAY SHAFT DRAFTS 41
6.3 DESIGN OF 2D LAY GEAR 1 42
6.4 DESIGN OF 2D LAY GEAR 2 43
6.5 DESIGN OF 2D OUTPUT SPUR GEAR 44
6.6 DESIGN OF 2D RING BEVEL 45

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 6.7 DESIGN OF 2D PINION BEVEL 46
6.8 DESIGN OF 2D PIN 1 47
6.9 DESIGN OF 2D PIN 2 48
6.10 DESIGN OF 2D BRACKET 49
6.11 DESIGN OF 2D OUTPUT GEAR LEFT 50
6.12 DESIGN OF 2D OUTPUT GEAR RIGHT 51
6.13 DESIGN OF 2D PINION SPUR 52
6.14 ORTHAGRAPHIC VIEW OF DIFFERENTIAL GEAR 53
6.15 SUMMARY 54
7 DESIGN ANALYSIS 55
7.1 STATIC ANALYSIS 55
7.1.1 BC AND CONSIDERATION 55
7.2 DYNAMIC ANALYSIS 58
7.2.1 BC AND CONSIDERATIONS 58
7.2.2 MESH PARAMETERS 58
7.3 TORSIONAL AND BENDING ANALYSIS 59
7.3.1 BCS AND CONSIDERATIONS 59
7.3.2 MESH PARAMETERS 59
7.4 CFD ANALYSIS 59
7.4.1 MESH PARAMETERS 60
7.5 MODAL ANALYSIS 61
7.6 SUMMARY 62
8 FABRICATION 63
8.1 SUMMARY 67
9 COST CALCULATION 68
9.1 SUMMARY 68
10 CONCLUSION 69
10.1 FUTURE SCOPE OF THE WORK 69
REFERENCES 70

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 LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1 Sectional View of ATV Gearbox 02
2 ATV Differential Unit 03
3 Components of a differential unit 05
4 Tyre slip due to loss of traction 06
5 Difference in velocity during a turn 06
6 Cageless differential unit 07
7 Lay Shaft 41
8 Lay Gear 1 42
9 Lay Gear 2 43
10 Output Spur Gear 44
11 Ring Bevel 45
12 Pinion Bevel 46
13 Pin 1 47
14 Pin 2 48
15 Bracket 49
16 Output Gear Left 50
17 Output Gear Right 51
18 Pinion Spur 52
19 Exploded View of Assembly 53
20 Isometric View of Gearbox with Integrated Open Differential
Unit 53
21 Front View of Gearbox with Integrated Open Differential Unit 53
22 Side View of Gearbox with Integrated Open Differential Unit 53
23 Right Side Casing 54
24 Left Side Casing 54
25 Assembled Views of Gearbox with Integrated Open Differential 54
Unit
26 Analysis of Gearbox Casing 56

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27 Analysis of Differential Gear 56
28 Analysis of First Reduction Gear 57
29 Analysis of Second Reduction Gear 57
30 Dynamic Analysis of Gears 58
31 Analysis of Lay Shaft 59
32 Mesh 60
33 Volumetric Fraction of Oil 61
34 Volumetric Fraction of Oil 61
35 Gearbox Casing Modal 62
36 Image of Output Gear (Left) 63
37 Image of Output Gear (Right) 63
38 Lay 1 and Lay 2 Gear 64
39 Output Spur Gear 64
40 Input Pinion 64
41 Pinion Gear 64
42 Pin 65
43 Spider Gear 65
44 Bracket 65
45 Ring Gear 66
46 Gunmetal Bush 66
47 Blackening Completed Components 66
48 Casing 66
49 Assembled Unit of Gearbox with Integrated Open Differential 67
Unit

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 LIST OF TABLES

TABLE NO. TITLE PAGE NO.

Table 4.1 Chemical Composition 26
Table 4.2 Mechanical Properties 26
Table 4.3 Physical Properties 27
Table 5.1 G.I.O.D.U. Specification 33
Table 7.1 Mesh Parameters for Transmission 56
Table 7.2 Slosh Mesh parameters 61
Table 9.1 Cost Calculation 69

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 LIST OF NOMENCLATURE

AISI - American Iron and Steel Institute

AR - Acceleration resistance
ATV - All-Terrain vehicle
CB - Coefficient depending on surface hardness
CNC - Computerized Numerical Control
CVT - Continuous Variable Transmission
Fa - Axial force
Fn - Normal force
FOS - Factor of Safety
Fr - Radial force
Ft - Tangential force
G.I.O.D.U. - Gearbox with Integrated Open Differential Unit
GR - Grade Resistance
GVW - Gross vehicle weight
HB - Brinell hardness
HRC - Hardness on Rockwell scale C
Kbl - Life factor for bending
kcl - Life factor for contact
Kg - kilogram
kmph - Kilometre per hour
kσ - Stress concentration factor for the fillet
LA - Longitudinal Acceleration
mm - Millimetre
mt - Transverse Module
MT - Twisting moment
Nm - Newton meter
PCD - Pitch Circle Diameter
Rad. - Radian

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RPM - Revolution per minutes
RR - Rolling Resistance
TR - Torque Resistance
TTE - Total Tractive Effect
WT - Weight transfer
α - Pressure angle
δ - Cone angle
σb - Bending stress
σc - Compressive stress
Hp - Horsepower
TE - Traction Effect
Z1 - No. of teeth in Pinion Gear
Z2 - No. of teeth in Differential Ring Gear
R - Cone distance
CB - Coefficient depending on surface hardness
HB - Brinell hardness
Kcl - Life factor for contact
kd - Dynamic load factor
WT - Weight transfer
b - Pinion gear face width
yv - Form factor based on equivalent number of teeth
n - Speed
@ - At the rate

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